Manufacturing apparatus of core material of vacuum heat insulating material, manufacturing method of vacuum heat insulating material, vacuum heat insulating material, and refrigerator

ABSTRACT

A manufacturing apparatus of a core material of a highly reliable vacuum heat insulating material having excellent workability, usability, and heat insulating performance is provided. The manufacturing apparatus of a core material of a vacuum heat insulating material related to the present invention includes: a reel for winding up a fiber assembly which has a predetermined width and is wound on a substantially cylindrical original fabric roll which has been cut to have a predetermined width, at a predetermined number of times; cutting means for cutting the fiber assembly which has been wound on the reel; and a forming member for forming the fiber assembly into a flat-plate-shaped core material after removing from the reel the fiber assembly which has been wound up on the reel at the predetermined number of times and been cut.

TECHNICAL FIELD

The present invention relates to a manufacturing apparatus of corematerial of vacuum heat insulating material, a manufacturing method ofvacuum heat insulating material, a vacuum heat insulating material and arefrigerator using the vacuum heat insulating material.

BACKGROUND ART

Conventionally, urethane foam has been used for heat insulating materialused for the heat insulating box of the refrigerator, etc. Recently,according to requests from the market for energy-saving or space-savingand capacity-increasing, instead of the urethane foam, anotherstructure, in which vacuum heat insulating material having heatinsulating performance being better than the urethane foam is embeddedin the urethane foam and used together, is used. Such vacuum heatinsulating material is also used for the refrigerator, etc.

The vacuum heat insulating material is formed by inserting powder, foam,fiber body, etc. as a core material in an outer cover material made of aplastic laminated film, etc. in which aluminum foil is used for a gasbarrier layer. Inside of the vacuum heat insulating material, the degreeof vacuum is kept to no more than some Pa (pascal).

Further, in order to suppress degradation of the degree of vacuum whichbecomes a cause of decreasing the heat insulating performance of thevacuum heat insulating material, adsorption agent to sorb gas or wateris provided in the outer cover material. For the core material of thevacuum heat insulating material, powder such as silica, foam such asurethane, and fiber body, etc. is used. Currently, glass fiber havingexcellent heat insulating performance is mainly used for the corematerial of the vacuum heat insulating material.

Elements of the fiber include inorganic fibers such as glass fiber,ceramic fiber, etc. (refer to Patent Literature 1 and Patent Literature8, for example).

Further, there are organic fibers such as polypropylene fiber,polylactate fiber, aramid fiber, LCP (liquid crystalline polymer) fiber,polyethylene terephthalate fiber, polyester fiber, polyethylene fiber,cellulose fiber, etc. (refer to Patent Literature 2 and PatentLiterature 7, for example).

Shapes of the fiber body include cottonlike, lamination of sheets (referto Patent Literature 3 and Patent Literature 4, for example), andlamination of sheets with alternating fiber orientations of sheets(refer to Patent Literature 5 and Patent Literature 6, for example).

Further, methods of laminating sheets include lamination by folding acontinuous belt-like sheet-shaped member alternatively in differentdirections so as to form the lamination (for example, refer to PatentLiterature 9).

CITATION LIST Patent Literature

-   -   [Patent Literature 1] JP 8-028776A    -   [Patent Literature 2] JP 2002-188791A    -   [Patent Literature 3] JP 2005-344832A    -   [Patent Literature 4] JP 2006-307921A    -   [Patent Literature 5] JP 2006-017151A    -   [Patent Literature 6] JP 7-103955B    -   [Patent Literature 7] JP 2006-283817A    -   [Patent Literature 8] JP 2005-344870A    -   [Patent Literature 9] JP 62-204093A

SUMMARY OF INVENTION Technical Problem

Like the above, for the currently used vacuum heat insulating material,the glass fibers are mainly used as the core material. However, sincethe glass fiber is stiff and brittle, at the time of manufacturing thevacuum heat insulating material, powder dust scatters to cause to stickto skin/mucous membrane of a worker, which may cause stimulus, and aproblem exists in the usability and workability.

Further, from the viewpoint of recycling, for example, the refrigeratoris demolished for each product in a recycle factory. At this time, theglass fiber is mixed with urethane waste, etc. and supplied to thermalrecycle. There is a problem that the recyclability of the glass fiber isnot good such that it causes to degrade the combustion efficiency, toremain as residue, etc.

On the other hand, in case of using polyester fiber for the corematerial, the usability and the recyclability are excellent. However,the vacuum heat insulating material using polyester fiber shows the heatconductivity which is an index representing the heat insulatingperformance is around 0.0030 [W/mK] (refer to Patent Literature 7, forexample). There is a problem that the vacuum heat insulating materialusing polyester fiber for the core material, compared with the generalvacuum heat insulating material using the glass fiber for the corematerial (the heat conductivity: around 0.0020 [W/mK]), shows worse heatinsulating performance.

Because of this, it is possible to improve the heat insulatingperformance by making the organic fiber layer thin and directing theorientation of the fibers in the direction being orthogonal to the heattransfer direction. However, in such a case, the number of laminatedsheets exceeds some hundreds, so that the productivity is bad. Further,for the bending process, since the number of laminated sheets is large,the bending is not easy, and the usability and the productivity are bad.

Further, in case of manufacturing the vacuum heat insulating material byinserting the core material such as glass fiber into the outer covermaterial such as aluminum foil laminated film, etc., and decompressingand sealing the inside, when the core material is inserted into theouter cover material such as aluminum foil laminated film, etc., inparticular when the inorganic fiber such as glass fiber is used for thecore material, there may be possibilities of the glass fiber penetratingthe outer cover material to damage or break the outer cover material, sothat the core material of the glass fiber is not directly inserted intothe outer cover material, but inserted into the outer cover materialwhile being set in a plastic bag, etc., which additionally requires theplastic bag, etc., complicates the manufacturing process of the corematerial or the vacuum heat insulating material, and further increasesthe manufacturing cost.

Further, as shown in Patent Literature 9, it is considered to form thecore material by folding the continuous belt-like sheet-shaped member(waste paper) alternatively in different directions with making foldinglines so as to laminate like layering; however, a folding apparatus isrequired for folding with making folding lines, and the foldingapparatus has a complicated structure and is expensive, therebyincreasing the cost.

Further, when the glass fiber is used for the core material of thevacuum heat insulating material, the glass fiber is excellent in heatinsulating performance. However, since the glass fiber is hard andbrittle, it is difficult to do folding processing after vacuuming.

Further, when the glass fiber is used for the core material of thevacuum heat insulating material, the glass fiber is excellent in heatinsulating performance. However, since the glass fiber is hard andbrittle, if the piping such as a condensation piping, etc. is insertedbetween the vacuum heat insulating material and the vacuum heatinsulating material for insulating heat, the vacuum heat insulatingmaterial cannot be deformed into a tubular shape, and thus there existsa gap corresponding to the diameter of the piping between the vacuumheat insulating materials. Accordingly, heat leakage may occur from thegap between the vacuum heat insulating materials, which degrades theheat insulating performance drastically.

Further, in case of using the organic fiber for the core material, whena plurality of sheets are laminated to form the core material, thevacuum heat insulating material becomes harder as the number oflaminated layers increases. Accordingly, when it is necessary to dofolding process after vacuuming, there is a problem that it is difficultto fold a part which needs to be folded, and the part which is notdesired to be folded may be deformed.

The present invention is provided to solve the above problems and aimsto provide a manufacturing apparatus of core material of the vacuum heatinsulating material including at least any of the features which will beshown below, a manufacturing method of the vacuum heat insulatingmaterial, the vacuum heat insulating material, and a refrigerator usingthe vacuum heat insulating material:

-   (1) having high heat insulating performance and excellent    productivity (in particular, productivity of the core material);-   (2) having high heat insulating performance, and excellent usability    and recyclability;-   (3) in case of using the organic fiber assembly for the core    material, having excellent productivity; and-   (4) being capable of manufacturing the core material according to    the size of the curve of folding process, and having easy    manufacturability.

Solution to Problem

A manufacturing apparatus of a core material of a vacuum heat insulatingmaterial related to the present invention includes: a reel winding up afiber assembly which has a predefined width and is wound on asubstantially cylindrical original fabric roll which has been cut tohave a predetermined width at a predetermined number of times; cuttingmeans cutting the fiber assembly which has been wound on the reel; andforming member forming the fiber assembly into a flat-plate-shaped corematerial after removing from the reel the fiber assembly which has beenwound up on the reel at the predetermined number of times and cut.

Advantageous Effects of Invention

According to the manufacturing apparatus of the core material of thevacuum heat insulating material of the present invention, it is possibleto manufacture the core material and the vacuum heat insulating materialwith a simple structure, and to reduce the manufacturing time. Further,since the winding is continuously done in the winding direction, it isunnecessary to cut the edge face in a length direction, therebysimplifying the equipment, and reducing the cutting time.

Further, by using the core material manufactured by the manufacturingapparatus of the vacuum heat insulating material of the presentinvention, it is possible to provide the vacuum heat insulating materialhaving excellent usability, heat insulating performance, orproductivity, and equipment which mounts this vacuum heat insulatingmaterial such as a refrigerator, etc.

BRIEF DESCRIPTION OF DRAWINGS

FIG. 1 shows the first embodiment and is a pattern diagram of a vacuumheat insulating material 7, and is a perspective view of a core material5 of the vacuum heat insulating material 7 made by laminating aplurality of non-woven cloth sheets.

FIG. 2 shows the first embodiment and is a pattern diagram of the vacuumheat insulating material 7, and is a side view showing orientation offiber in one non-woven cloth sheet.

FIG. 3 shows the first embodiment and is a pattern diagram of the vacuumheat insulating material 7, and is a side view showing orientationsituation of fiber when the core material 5 is thick.

FIG. 4 shows the first embodiment and is an exploded perspective viewshowing a structure of the vacuum heat insulating material 7.

FIG. 5 shows the first embodiment and is a perspective view showing bypattern a lamination state of the core material 5 that forms the vacuumheat insulating material 7.

FIG. 6 shows the first embodiment and is a perspective view showing bypattern an original fabric roller and a reel of a laminating device ofthe core material 5 which forms the vacuum heat insulating material 7.

FIG. 7 shows the first embodiment and is a diagram showing a structureof a reel of a vacuum heat insulating material manufacturing apparatus,in which (a) of FIG. 7 shows a state of the reel when winding up anorganic fiber assembly; and (b) of FIG. 7 shows a state of the reel whenremoving (separating) the reel from a sheet-shaped fiber assembly 1Jafter winding up the continuous sheet-shaped fiber assembly 1J.

FIG. 8 shows the first embodiment and is a diagram showing a clampmember for clamping an organic fiber assembly wound up on the reel ofthe vacuum heat insulating material manufacturing apparatus.

FIG. 9 shows the first embodiment and is a diagram showing amanufacturing method of the vacuum heat insulating material.

FIG. 10 shows the first embodiment and is a pattern diagram showinganother reel.

FIG. 11 shows the first embodiment and is a diagram showing a structureof a combined original fabric roll having a large width made bycombining a plurality of original fabric rolls.

FIG. 12 shows the first embodiment and is a pattern diagram of a windingdevice when the winding device uses two combined original fabric rollsand winds up the combined original rolls on a reel.

FIG. 13 shows the first embodiment and is a pattern diagram showing astructure of an organic fiber assembly wound by the winding device usingtwo combined original fabric rolls (the upper side original fabric rolland the lower side original fabric roll).

FIG. 14 shows the first embodiment and is a cross sectional view of thecore material wound by the winding device using two combined originalfabric rolls.

FIG. 15 shows the first embodiment and is a perspective view of a corematerial 550 when the core material 550 is produced by using and windingup three combined original fabric rolls on the reel.

FIG. 16 shows the first embodiment and is a diagram explaining astructure of another combined original fabric roll.

FIG. 17 shows the first embodiment and is a perspective view showing astate in which a vacuum heat insulating material 750 is folded.

FIG. 18 shows the first embodiment and is a diagram of the vacuum heatinsulating material 750 when viewed from a width direction.

FIG. 19 shows the first embodiment and is a cross sectional view of arefrigerator 100.

FIG. 20 shows the first embodiment and is a pattern diagram of thewinding device when the winding device winds up on the reel 1311 atleast one original fabric roll 1307 having the first predetermined widthand at least one combined original fabric roll 1305 made by combiningoriginal fabric rolls having a width smaller than the firstpredetermined width so as to have substantially the same width as thefirst predetermined width, which is a diagram showing a manufacturingmethod of another core material of the present embodiment.

FIG. 21 shows the first embodiment and is a perspective view of the corematerial manufactured by using and winding up on a reel at least oneoriginal fabric roll 1307 having the predetermined width and at leastone combined original fabric roll.

FIG. 22 shows the first embodiment and is a cross sectional view of thecore material manufactured by using and winding up on the reel at leastone original fabric roll having the predetermined width and at least onecombined original fabric roll.

FIG. 23 shows the first embodiment and is a perspective view of thevacuum heat insulating material using the core material produced byusing and winding up on the reel at least one original fabric rollhaving the predetermined width and at least one combined original fabricroll.

FIG. 24 shows the first embodiment and is a pattern diagram showing ashape of the vacuum heat insulating material.

DESCRIPTION OF EMBODIMENTS

Embodiment 1

FIGS. 1 through 4 show the first embodiment; FIG. 1 is a pattern diagramof a vacuum heat insulating material 7 and is a perspective view of acore material 5 of the vacuum heat insulating material 7 made bylaminating a plurality of non-woven cloth sheets; FIG. 2 is a patterndiagram of the vacuum heat insulating material 7, and is a side viewshowing an orientation of fabric in one sheet of non-woven cloth; FIG. 3is a pattern diagram of the vacuum heat insulating material 7, and is aside view showing an orientation situation of fabric when the corematerial 5 is thick; and FIG. 4 is an exploded perspective view showinga structure of the vacuum heat insulating material 7.

(Laminated Structure)

In FIG. 1, the core material 5 has a laminated structure made bylaminating sheet-shaped organic fiber assembly (hereinafter, “organicfiber assembly 1”), of which, for example, at least one end face 1 a iscut off. That is, the core material 5 shown in FIG. 1 is formed to besheet-shaped by laminating a plurality of layers of substantiallyrectangular organic fiber assembly 1 and then cutting four sides of thesubstantially rectangular shape. Or, the substantially rectangularsheet-shape is formed by cutting the four sides of the substantiallyrectangular organic fiber assembly 1 and then laminating a plurality oflayers.

In FIG. 2, the organic fiber assembly 1 is formed by a plurality oforganic fibers 2 x which are arranged with a predetermined interval anda plurality of organic fibers 2 y which are arranged with apredetermined interval in a direction being approximately orthogonal tothe organic fibers 2 x.

At this time, the organic fibers 2 x and the organic fibers 2 y makeapproximate point contact. Among the organic fibers 2 y, an air layer 3being a heat insulated room is formed.

As a collective term of the organic fibers 2 x and the organic fibers 2y, the organic fibers 2 are used.

Here, as shown in FIG. 3, if the thickness of one sheet (the organicfiber assembly 1) is increased, the fiber tends to be orientated to athickness direction which is a heat transfer direction. In particular,when the organic fibers 2 (sometimes called simply as a fiber) is ashort fiber having a short fiber length (for example, the fiber lengthis around 5 to 150 mm), the short fiber tends to be orientated to thethickness direction which is the heat transfer direction. Through thisshort fiber, heat is transferred from a front surface of the sheet to arear surface (shown by the arrow in FIG. 3), and heat insulatingperformance is degraded.

Accordingly, by thinly laminating the organic fiber assembly 1 to makeit thin-sheet-shaped, it is possible to prevent the fiber from beingmade orientated to the heat transfer direction (the laminating directionof fibers of the organic fiber assembly 1; the thickness direction ofthe sheet-shaped organic fiber assembly 1). Thereby, degradation of heatinsulating performance caused by heat transfer through the fiberorientated to the heat transfer direction can be suppressed. Therefore,a heat conductivity of the core material 5 can be made small, whichenables to increase the heat insulating performance.

In FIG. 2, an arrow in a solid line and an arrow in a broken line showthe heat transfer direction. Since the organic fibers 2 x and theorganic fibers 2 y are substantially orthogonal, a contacting part ofthe organic fibers 2 x and the organic fibers 2 y become point contact,and thus heat resistance is increased and the heat insulatingperformance is improved.

Here, the above shows a case when the organic fibers 2 x and the organicfibers 2 y intersect substantially orthogonal, however, the presentembodiment is not limited to this case. The organic fibers 2 x and theorganic fibers 2 y can be intersect with each other at an angle otherthan a right angle. It is sufficient that all of the organic fibers 2 xand all of the organic fibers 2 y are not placed in parallel. Only ifthe degradation of heat insulating performance caused by the heattransfer through the fiber orientated to the heat transfer direction canbe suppressed a little bit, it is possible to improve the heatinsulating performance.

In FIG. 4, the vacuum heat insulating material 7 has a gas barriercontainer (“an outer cover material 4”, hereinafter) having air barrierproperties, a core material 5 and an adsorption agent 6 (gas absorbentor water absorbent (CaO), for example) sealed inside of the outer covermaterial 4. The inside of the outer cover material 4 is decompressed toa predetermined degree of vacuum (some Pa (pascal) to some hundreds Pa).

(Organic Fiber)

As for material used for the organic fibers 2 which forms the corematerial 5 of the vacuum heat insulating material 7, polyester, andothers such as polypropylene, polylactate, aramid, LCP (liquidcrystalline polymer), PPS (polyphenylene sulfide), polystyrene, etc. canbe used. Further, if the heat-resistant properties of the core material5 are desired to be increased, heat-resistant resin such as LCP (liquidcrystalline polymer), PPS (polyphenylene sulfide), etc. should be usedfor the organic fibers 2. Further, if the compressive creep propertiesare desired to be increased, fibers having a large fiber diameter shouldbe used. Further, if the above resins are mixed and used, the vacuumheat insulating material 7 having excellent compressive creepproperties, high heat-resistance, and high heat insulating propertiescan be obtained. Polystyrene has small solid heat conductivity, and itis expected that the heat insulating performance can be improved, andthe manufacturing can be done with a low cost.

Since polypropylene has low hygroscopic property, it is possible toreduce time for drying or vacuuming by using polypropylene and theproductivity can be improved. Further, since polypropylene has smallsolid heat conductivity, it is possible to expect the improvement ofheat insulating performance of the vacuum heat insulating material 7.

Further, since polylactate has biodegradability, after use of theproduct, the disorganized and sorted core material can be processed bydisposal by landfill.

Further, since aramid or LCP has high stiffness, shape retentioncapacity is good when is vacuum-packed and is applied with air pressure,and the porosity can be increased, and there is a merit that it ispossible to expect the improvement of the heat insulating performance,etc.

The core material 5 serves, for example, in the vacuum heat insulatingmaterial 7 which uses a plastic laminating film for the outer covermaterial 4, a role to secure a space within the vacuum heat insulatingmaterial 7 for supporting air pressure, and another role to reduce theheat conduction of gas by precisely dividing the space. Here, from aview point of heat conduction control of gas, it is desirable thatspatial distance should be made smaller than free travel distance of airmolecule at the degree of vacuum.

In this embodiment, since the organic fibers 2, for example, are usedfor the core material 5 of the vacuum heat insulating material 7, whencompared with a case in which hard and brittle glass fiber is used asthe core material, at the time of manufacturing the vacuum heatinsulating material 7, powder dust does not scatter and does not stickto the skin/mucosal membrane of a worker to cause irritation, and thususability and workability can be improved.

(Manufacturing Method of Fiber Assembly Material (Original Fabric RollMaterial))

The organic fiber assembly 1 (organic fiber assembly, the same as thesheet-shaped assembly) which forms the core material 5 is manufacturedby making heated and melted polyester resin or polystyrene resin fallfreely on a conveyer from a number of nozzles aligned with respect to awidth which is desired to be produced and with feeding the conveyer atan arbitrary speed, compressing the heated and melted polyester resin orpolystyrene resin by a pressure roller and winding up on a cylindricaloriginal fabric roller to manufacture a substantially cylindricaloriginal fabric roll material. The bulk density of the organic fiberassembly 1 is adjusted by discharge amount of the melted resin and thespeed of the conveyer, and it is possible to obtain fiber assemblieshaving different thickness.

Further, as for long fiber non-woven cloth which is the organic fiberassembly 1, continuous fiber melted and extruded by an extruder from aspinning nozzle is collected on the conveyer, the conveyer is fed at anarbitrary speed to get sheet-shaped form, and long fibered non-wovencloth which can be wound up on the original fabric roller is obtained.Since the continuous sheet-shaped organic fiber assembly 1 formed out ofthe continuous organic fiber 2 is obtained, it is possible to wind up onthe cylindrical original fabric roller continuously, which enables toobtain the original fabric roll of the long fibered non-woven cloth.

Further, for fiber spinning, a method can be used, after cooling theresin by cold air, etc. directly under the nozzle, by stretching theresin with compressed air, etc. to fiberize; and another method byblowing, from the side of a nozzle hole, the resin with high-temperatureair which is as high as the melting temperature of the resin.

Here, the organic fiber assembly 1 obtained by the above methods may bedifficult to handle at the time of manufacturing the vacuum heatinsulating material 7, since organic fibers 2 are disjointed with eachother. Then, at the time of applying pressure, the organic fibers 2 canbe heat-deposited. At this time, applying excessive pressure, orexcessive heat-deposition may increase a contacting area between theorganic fibers 2, increase heat transfer, and generate heat conductionfrom the welding unit, which degrades the heat insulating performance.Therefore, the contacting area between the organic fibers 2 should bemade small as much as possible. The contacting area between the organicfibers 2 is desired to be no more than 20% of the total area (the sheetarea), preferably no more than 15%, more preferably no more than 8%.

Since it is confirmed that when a rate occupied by the heat depositionexceeds 20% of the total area (the sheet area), the heat conductivitybecomes large, and the heat insulating performance is degraded, the rateoccupied by the heat deposition is preferably no more than 20% of thetotal area (the sheet area). Here, if the rate of the occupied by theheat deposition to the total area (the sheet area) is made small, theheat insulating performance is extremely improved, so that it is desiredthat the rate occupied by the heat deposition is suppressed to be nomore than 15% of the total area (the sheet area), and further, no morethan 8% of the total area (the sheet area).

As for the heat deposition, an embossing is done by, for example, addingdotted welded spots with a heat roller, etc., long-fibered non-wovencloth (the organic fiber assembly 1) which is windable and has a goodheat insulating performance can be obtained, while securing handlingstrength. Here, in the present embodiment, the temperature of the heatroller can be about 195 degrees Celsius.

Here, instead of the heat deposition, needlepunching method can be usedto form to be sheet-shaped by repeating piercing and raising verticallymultiple pins with a hook to get fibers entangled with each other,thereby preventing fibers from being dispersed. However, it ispreferable to form to be sheet-shaped by the heat deposition (forexample, the embossing), since it can be implemented with simpleequipment and working is easy on a conveyer.

(Fiber Diameter)

In this first embodiment, as the fiber assembly, for example, theorganic fiber assembly 1 is used. The fiber diameter of the organicfiber assembly 1 is adjusted by the nozzle diameter for forming theassembly so as to be about 15 μm. As for the heat insulatingperformance, the smaller the fiber diameter is, the better the heatinsulating performance is. Theoretically, the fiber diameter is desiredto be small due to the relation between the degree of internal vacuum ofthe vacuum heat insulating material 7 with the spatial distancesegmented by fibers, and with a free travel distance of gas molecule.The fiber diameter is desired to be no more than 15 μm, preferably nomore than 10 μm; the average fiber diameter of around 9 μm can besuitably used.

The measurement of the average fiber diameter can be done by measuringdiameters of some to some tens of positions (ten positions, for example)using a microscope, and an average value can be employed. Further,fabric weight (weight (g) of fiber per 1 m²) can be obtained as a weightper unit area of one sheet by measuring an area and a weight of onesheet.

In the present embodiment, by regulating an orientation direction offiber to substantially orthogonal to the thickness direction which isheat insulating direction, a plurality of the organic fiber assemblies 1are laminated to form a multi-layered structure.

Further, when short fibered non-woven cloth is used for the organicfiber assembly 1, since the fiber length is short, the organic fibers 2x and the organic fibers 2 y tend to be orientated in the heatinsulating direction (the thickness direction of sheet). In order tosuppress degradation of the heat insulating performance due to the heattransfer through the fibers orientated in the heat insulating direction,long-fibered non-woven cloth, which uses long fiber, is used for theorganic fiber assembly 1.

In the present embodiment, as for the fiber length, at leastsubstantially the same length as the length of the sheet is used, andthus it is prevented that fiber may be torn halfway in the sheet and apart (a mid) or an end of the fiber may be orientated in the heatinsulating direction so that the heat insulating performance is notdegraded.

(Laminating Method of Fiber Assembly, Manufacturing Method 1 of CoreMaterial)

Next, the obtained sheet-shaped organic fiber assembly 1 is cut (cutout) with an end face 1 a so as to be, for example, a predetermined size(width 210 mm×length 297 mm). By laminating these into a plurality oflayers (twenty-five layers, for example), the core material 5 is formed,which has a predetermined size and a predetermined thickness, and ofwhich an end surface 5 a is cut. The core material 5 can be formed bycutting an end face 5 a to become a predetermined size after laminatinga plurality of layers of the sheet-shaped organic fiber assembly 1.Here, the number of sheets to be laminated can be set arbitrarily basedon the thickness of the organic fiber assembly 1 obtained and thethickness of the vacuum heat insulating material 7 which is desired tobe manufactured.

(Outer Cover Material)

For the outer cover material 4 (FIG. 4) of the vacuum heat insulatingmaterial 7, a laminated film having the thickness of at least 5 μm andno more than 100 μm is used. In the present embodiment, for example, agas-barrier plastic laminated film structured by nylon (6 μm), aluminumevaporated PET (polyethylene telephthalate) (10 μm), aluminum foil (6μm), and high-density polyethylene (50 μm) is used.

Other than the above, if the laminated film without including a aluminumfoil such as polypropylene, polyvinyl alcohol, or polypropylenestructure, etc. is used for the outer cover material 4 of the vacuumheat insulating material 7, it is possible to suppress the degradationof the heat insulating performance caused by heat bridge. Here, threesides out of four sides of the outer cover material 4 are heat-sealed bya seal packaging machine. The remaining one side is heat-sealed afterthe core material 5 is inserted.

(Manufacturing Method 1 of Vacuum Heat Insulating Material)

As for manufacturing the vacuum heat insulating material 7, first, thecore material 5 having a predetermined size and thickness is insertedinto a bag-shaped outer cover material 4 having an opening part 4 a. Theouter cover material is fixed so as not to close the opening part 4 a,and dried in a constant temperature reservoir at the temperature ofabout 105 degrees Celsius for a half day (about 12 hours). Then, inorder to absorb remained gas after vacuum packaging, outgassing from thecore material 5 over time, and gas permeating through a seal layer ofthe outer cover material 4, adsorption agent 6 (gas adsorption agent orwater adsorption agent, etc.) is inserted in the outer cover material 4(a filmed bag), and vacuuming (decompression treatment) is done usingKashiwagi-style vacuum packaging machine (KT-650 manufactured by NPCIncorporated). The vacuuming is done until the degree of vacuum in thechamber becomes about 1 to 10 Pa, and then the opening part 4 a of theouter cover material 4 (the filmed bag) is heat-sealed in the chamber,thereby obtaining a plate-shaped vacuum heat insulating material 7.

(Laminating Method of Fiber Assembly, Manufacturing Method 2 of CoreMaterial)

As has been discussed, the core material 5 can be formed by cutting thesheet-shaped organic fiber assembly 1 into the predetermined size andlaminating a plurality of layers of the sheet-shaped organic fiberassembly 1 to manufacture the vacuum heat insulating material 7, andalso the core material 5 can be made by laminating a plurality of layersof the sheet-shaped organic fiber assemblies 1 and then cutting the endface 5 a to form into the predetermined size to manufacture the vacuumheat insulating material 7. Here, another manufacturing method of thecore material 5 will be explained. A manufacturing method of the corematerial 5 by continuously winding up the continuous sheet-shaped fiberassembly (for example, the organic fiber assembly 1) will be explained.

FIGS. 5 and 6 show the first embodiment; FIG. 5 is a perspective viewshowing by pattern a laminating state of the core material 5 that formsthe vacuum heat insulating material 7, and FIG. 6 is a perspective viewshowing by pattern an original fabric roller and a reel of a laminatingdevice of the core material 5 that forms the vacuum heat insulatingmaterial 7.

In FIGS. 5 and 6, the continuous sheet-shaped fiber assembly 1J (forexample, the organic fiber assembly 1, the thickness of which is atleast around 30 μm and no more than around 500 μm, preferably at leastaround 80 μm and no more than around 300 μm) formed by continuous fiber(for example, the organic fiber 2) is wound up on the reel 1311 (aftercontinuously winding up on the reel 1311) with a predetermined tensionalforce. The predetermined tensional force is sufficient to prevent thecontinuous sheet-shaped fiber assembly 1J from being cut while beingwound or, even if the fiber assembly is not cut, from being too muchstretched to keep its properties which are necessary as a fiber. Thecontinuous sheet-shaped fiber assembly 1J is formed into a flat plateshape, and the core material 5 is produced. That is, the core material 5is constituted by a laminated structure of the continuous sheet-shapedfiber assembly 1J formed by winding up the sheet-shaped fiber assembly1J which is continuous in the length direction (the winding direction)continuously from the inside toward the outside. Here, it is assumedthat the width of the flatly formed core material 5 is H, the length isL, and the thickness is t (refer to FIG. 5). Further, an end portion ofend-winding of the core material 5 is called as an end-winding endportion 1Je.

The core material 5 is formed by, for example, winding up the continuoussheet-shaped fiber assembly 1J (the original fabric roll 1301), havingthe predetermined width wound on the substantially cylindrical originalfabric roller 1302, on the reel 1311 continuously at a plurality oftimes (in the state of being continuously wound up at a predeterminednumber of times), taking off the reel 1311 from the continuoussheet-shaped fiber assembly 1J in the shaft center direction of the reel1311 (in the shaft center direction of a rotating shaft 1315 which isdisplaced by around 90 degrees from the winding direction), andflattening (into a sheet shape) the continuous sheet-shaped fiberassembly 1J wound substantially cylindrically. The flat core material 5is formed in a flat plate shape (sheet-shaped, smooth) including a flatpart 5 g (a smooth part) made by laminating a plurality of layers of thecontinuous sheet-shaped fiber assembly 1J to become flat (smooth) and afolding end portion 5 f (a folding part) formed by folding thecontinuous sheet-shaped fiber assembly 1J at both end sides in thelength direction of the flat part 5 g (since the continuous sheet-shapedfiber assembly 1J is continuously wound in the winding direction, thecontinuous sheet-shaped fiber assembly 1J is folded and wound at theboth end sides of the flat shape in the winding direction).

At this time, the number of times R of winding on the reel 1311 isdetermined so as to have the predetermined thickness t when the corematerial 5 is formed in a flat plate shape and sealed in the outer covermaterial 4 in a substantially vacuum state. For example, if thenecessary thickness t of the core material 5 (the predeterminedthickness of the core material 5) is 8 mm and the thickness of one sheetof the continuous sheet-shaped fiber assembly 1J is 80 μm, the necessarynumber of laminating sheets becomes 100 sheets (8 mm/80 μm), and thenecessary predetermined number of times R of winding on the reel 1311becomes 50 times which corresponds to 50 sheets of the continuoussheet-shaped fiber assembly 1J. Since the core material 5 is formed byflattening the core material 5 (cylindrical) when the reel 1311 is takenoff so as to form into a flat plate shape (sheet-shaped), the thicknesst of the core material 5 becomes the thickness of 100 sheetscorresponding to twice of 50 times which is the number of times R woundon the original fabric roll 1301, and the core material 5 is formed intoa laminated structure having a plurality of layers of the continuoussheet-shaped fiber assembly 1J (lamination of 100-sheet layers which isthe predetermined number of sheets).

Further, the necessary width (the predetermined width) H of the corematerial 5 is appropriately adjusted according to the width of thecontinuous sheet-shaped fiber assembly 1J (the original fabric roll1301) wound on the original fabric roller 1302 or the width of the reel1311. For example, if the necessary width H (the predetermined width) ofthe core material 5 is 1500 mm, the width of the reel 1311 can be set toaround 1500 mm which is the predetermined width, or the width (forexample, around 1520 mm) being slightly larger than 1500 mm which is thepredetermined width, and unnecessary parts (both ends in the widthwisedirection) can be cut off.

FIGS. 7 and 8 show the first embodiment; FIG. 7 is a diagram showing astructure of the reel of the vacuum heat insulating materialmanufacturing apparatus, in which (a) of FIG. 7 shows a state of thereel when winding up the continuous sheet-shaped fiber assembly 1J, and(b) of FIG. 7 shows a state of the reel when removing (separating) thereel from the continuous sheet-shaped fiber assembly 1J after winding upthe continuous sheet-shaped fiber assembly 1J; FIG. 8 is a diagramshowing a clamp member for clamping the organic fiber assembly wound upon the reel of the vacuum heat insulating material manufacturingapparatus.

In the present embodiment, the reel 1311 is, for example, substantiallycylindrical, which is divided by, for example, a plurality ofcircumferential members 1312 in the circumferential direction. Forexample, the reel 1311 is divided into four by circumferential members1312 a, 1312 b, 1312 c, and 1312 d. In FIG. 7, the circumferentialmembers 1312 are not shown; the circumferential members 1312 a, 1312 b,1312 c, and 1312 d are called generally as “the circumferential member1312”. Here, in the circumferential member 1312, at around substantiallycenter of the inner circumferential side of the plurality of dividedcircumferential members 1312 a, 1312 b, 1312 c, and 1312 d in therespective circumferential direction, circumferential member retainingshafts 1316 (circumferential member retaining shafts 1316 a, 1316 b,1316 c, and 1316 d) connected to the rotating shaft 1315 of the reel1311 are respectively provided. That is, the plurality ofcircumferential members 1312 are connected to or retained by therotating shaft 1315 of the reel 1311 through the circumferential memberretaining shafts 1316. To the rotating shaft 1315 of the reel 1311, adrive shaft driven by a motor, etc. is inserted or connected.

At least one circumferential member (in the present embodiment, twocircumferential members 1312 a and 1312 b opposing in the radialdirection) of the plurality of divided circumferential members 1312 (inthe present embodiment, four circumferential members 1312 a, 1312 b,1312 c, and 1312 d), the circumferential member retaining shafts 1316(in the present embodiment, the circumferential member retaining shafts1316 a and 1316 b) which is extendable/contractable or movable in theradial direction are provided. Thus, the circumferential memberretaining shafts 1316 and 1316 b are moved in the contracting directiontoward the center side of radial direction after winding up thecontinuous sheet-shaped fiber assembly 1J on the reel 1311, therebyreleasing the tensional force of the continuous sheet-shaped fiberassembly 1J which is wound substantially cylindrically on the reel 1311with the predetermined tensional force, and further taking off thecontinuous sheet-shaped fiber assembly 1J wound substantiallycylindrically from the reel 1311 in the shaft core direction of therotating shaft 1315. That is, the tensional force of the continuoussheet-shaped fiber assembly 1J which is wound on the reel 1311 with thepredetermined tensional force is released, thereby easily taking off thecontinuous sheet-shaped fiber assembly 1J which is wound on the reel1311 from the reel 1311. The continuous sheet-shaped fiber assembly 1Jcan be easily removed without damage.

Here, at least one clamp member 1320 for retaining or fixing thesubstantially cylindrical organic fiber assembly 1 after taking off thereel 1311 is provided at the reel 1311. In the present embodiment, theclamp members 1320 are provided detachably at clamp member setting parts1313 c and 1313 d, which are respectively provided at least twopositions (at two opposing positions) of the circumferential members1312 c and 1312 d, or circumferential member retaining shafts 1316 c and1316 d. Further, two clamp member setting parts 1313 c and 1313 d areprovided at different positions (for example, different circumferentialmember retaining shafts 1316 c and 1316 d) from the circumferentialmember retaining shafts 1316 (in the present embodiment, thecircumferential member retaining shafts 1316 a and 1316 b) which areextendable/contractable and movable in the radial direction.

The clamp member 1320 is provided between the inner circumferential sideof the substantially cylindrical continuous sheet-shaped fiber assembly1J and the outer circumferential side of the reel 1311 for retaining orfixing (for example, retaining or fixing by holding) the continuoussheet-shaped fiber assembly 1J when the continuous sheet-shaped fiberassembly 1J is wound on the reel 1311 substantially cylindrically. Theclamp member 1320 is, for example, rod-shaped or plate-shaped. The clampmember 1320 can be provided at the reel 1311 side with being detachablefrom the reel 1311 before the continuous sheet-shaped fiber assembly 1Jis wound. The clamp member 1320 can be provided, while the continuoussheet-shaped fiber assembly 1J is wound on the reel 1311, at, forexample, two clamp member setting parts 1313 (for example, the clampmember setting parts 1313 c and 1313 d respectively provided at thecircumferential members 1312 c and 1312 d or the circumferential memberretaining shafts 1316 c and 1316 d) between the continuous sheet-shapedfiber assembly 1J (the inner circumferential side) and the reel 1311(the outer circumferential side), so as to be inserted from the axialdirection of the rotating shaft 1315, to retain the continuoussheet-shaped fiber assembly 1J. The clamp member 1320 can be alsoprovided to retain by holding the continuous sheet-shaped fiber assembly1J at two positions using the two clamp member setting parts 1313 (forexample, the clamp member setting parts 1313 c and 1313 d). Here,although the clamp member setting part 1313 is not shown in FIG. 8, theclamp member setting parts 1313 c and 1313 d are generally called as“the clamp member setting part 1313”.

Here, in the present embodiment, on the reel 1311, at the outercircumferential face side of the circumferential member 1312 (forexample, the circumferential members 1312 c and 1312 d which are notmovable in the radial direction) at which the clamp member 1320 isprovided, the clamp member setting part 1313 (for example, a concavepart or a notch, etc. provided to have, for example, a predeterminedwidth (or a length) toward the direction of the rotating shaft 1315),which can contain or insert the clamp member in the axial direction ofthe rotating shaft 1315 of the reel 1311, is provided.

The clamp member 1320 which is contained or inserted in the clamp membersetting part 1313 (for example, 1313 c, 1313 d) is, for example,rod-shaped or plate-shaped. The clamp member 1320 can be provided at theclamp member setting part 1313 (the clamp member setting parts 1313 cand 1313 d) before the continuous sheet-shaped fiber assembly 1J iswound up on the reel 1311. After winding up the continuous sheet-shapedfiber assembly 1J on the reel 1311, the circumferential members 1312 aand 1312 b are moved to the center direction (the contracting direction)in the radial direction, and the tensional force of the substantiallycylindrical continuous sheet-shaped fiber assembly 1J which is wound upon the reel 1311 with the predetermined tensional force is released. Thecontinuous sheet-shaped fiber assembly 1J is clamped by the clamp member1320 (clamped at least two positions (the clamp member setting parts1313 c and 1313 d) in the present embodiment), and the continuoussheet-shaped fiber assembly 1J can be removed from the reel 1311.

In another way, after the continuous sheet-shaped fiber assembly 1J iswound up on the reel 1311 with the predetermined tensional forcesubstantially cylindrically, at least one clamp member 1320 is insertedfrom the axial direction of the rotating shaft 1315 of the reel 1311 toa concave part or a notch, etc. of the clamp member setting part 1313(the clamp member setting parts 1313 c and 1313 d) provided at thecircumferential members 1312 c and 1312 d, which are not movable, of thereel 1311, located between the inner circumferential side of thecontinuous sheet-shaped fiber assembly 1J and the outer circumferentialside of the reel 1311. The substantially cylindrical continuoussheet-shaped fiber assembly 1J is clamped (clamped at least twopositions (the clamp member setting parts 1313 c and 1313 d) in thepresent embodiment). Then the circumferential members 1312 a and 1312 bare moved to the center direction (the contracting direction) in theradial direction, thereby releasing the tensional force of thesubstantially cylindrical continuous sheet-shaped fiber assembly 1Jwhich is wound up on the reel 1311 with the predetermined tensionalforce, and removing the reel 1311.

Here, at least one clamp member 1320 (in the present embodiment, twoclamp members 1320 c and 1320 d) is provided so as to be detachable fromthe reel 1311, namely, it is provided at least one circumferentialmember (in the present embodiment, two circumferential members 1312 cand 1312 d), which is not movable, of the reel 1311.

In this manner, at least one movable circumferential member 1312 a or1312 b is moved in the direction of releasing the tensional force,thereby easily releasing the tensional force of the substantiallycylindrical continuous sheet-shaped fiber assembly 1J which is wound upon the reel 1311 with the predetermined tensional force. Therefore, thecontinuous sheet-shaped fiber assembly 1J can be easily removed from thereel 1311 without breaking or damaging the continuous sheet-shaped fiberassembly 1J or the organic fiber 2. It is possible to obtain the highlyreliable winding device with a simple structure, further the highlyreliable continuous sheet-shaped fiber assembly 1J or the vacuum heatinsulating material 7 with a low cost.

Here, the positions, at which the continuous sheet-shaped fiber assembly1J is clamped, are at two positions which divide the circumferentiallength of the cross-sectional circle of the substantially cylindricalfiber assembly 1J into substantially two equal parts with substantiallythe same length in the circumferential direction (the cross sectionalshape of the cross section at substantially right angle with respect tothe axial direction of the rotating shaft 1315 of the reel 1311 (in caseof the substantially cylindrical fiber assembly, the cross sectionalshape becomes a substantially circular shape), two positions (in case ofa circle, two positions intersecting a circumference) at which astraight line passing the center of rotation of the rotating shaft 1315of the reel 1311 intersect with the cross sectional shape (an externalshape of the cross section; a circumference in case of a circle).

Therefore, since the clamping positions are two positions which dividethe circumferential length of the external shape (in case of thesubstantially cylindrical fiber assembly, a circle) of the cross sectionof the substantially cylindrical shape into substantially two equalparts, while keeping a state in which the continuous sheet-shaped fiberassembly 1J is clamped by the two clamp members 1320 (the clamp members1320 c and 1320 d), the continuous sheet-shaped fiber assembly 1J isseparated from the reel 1311, the two clamp members 1320 c and 1320 dare made movable or moved in the opposite sides directions ofsubstantially straight line direction (at substantially 180 degrees inthe opposite direction). The continuous sheet-shaped fiber assembly 1Jbeing wound up a plurality of times and laminating a plurality of layersis pulled by the two clamp members 1320 c and 1320 d in the oppositedirections, and thus the continuous sheet-shaped fiber assembly 1J isformed in a flat plate shape with being folded at the parts clamped bythe clamp members 1320 c and 1320 d. Then, the clamp members 1320 (theclamp members 1320 c and 1320 d) are removed from the continuoussheet-shaped fiber assembly 1J formed in a flat plate shape bylaminating a plurality of layers, the plurality of layers of thecontinuous sheet-shaped fiber assembly 1J are laminated while beingcontinuously sheet-shaped, and the flat core material 5 having thepredetermined width H and the predetermined length L is formed, that isfolded at a folding end portion 5 f and that has a flat plate (sheet)shaped flat part 5 g.

(Manufacturing Method 2 of Vacuum Heat Insulating Material)

Next, based on FIG. 9, the manufacturing method of the vacuum heatinsulating material 7 according to the present embodiment will beexplained. FIG. 9 shows the first embodiment and shows the manufacturingmethod of the vacuum heat insulating material. In FIG. 9, (a) to (h) ofFIG. 9 show processes of manufacturing the vacuum heat insulatingmaterial 7. (a) of FIG. 9 shows a start-winding step for startingwinding up the continuous sheet-shaped fiber assembly 1J (for example,the organic fiber assembly 1 produced by the continuous organic fiber 2,a non-woven cloth sheet) on the reel 1311. The original fabric roll1301, being formed by winding up the continuous sheet-shaped fiberassembly 1J at a plurality of times and cut to have the predeterminedwidth, and the reel 1311, having the predetermined width for winding upthe continuous sheet-shaped fiber assembly 1J wound on the originalfabric roll 1301, are provided. The original fabric roll 1301 and thereel 1311 are rotated, thereby starting winding up on the reel 1311 ofthe continuous sheet-shaped fiber assembly 1J wound on the originalfabric roll 1301. This process is the start-winding step.

(b) of FIG. 9 is an end-winding step for finishing winding up after thecontinuous sheet-shaped fiber assembly 1J is wound up on the reel 1311at the predetermined number of times R. At the start-winding step, thecontinuous sheet-shaped fiber assembly 1J is wound up on the reel 1311from the original fabric roll 1301; at this time, a thickness a (notshown) of the continuous sheet-shaped fiber assembly 1J wound up on thereel 1311 becomes the thickness t/2 which corresponds to a half of thenecessary predetermined thickness t of the core material 5. Afterwinding up at the predetermined number of times R corresponding to thepredetermined thickness a, the rotations of the original fabric roll1301 and the reel 1311 halt, thereby finishing the winding up of thecontinuous sheet-shaped fiber assembly 1J. This process is theend-winding step.

(c) of FIG. 9 is a cutting step for cutting the continuous sheet-shapedfiber assembly 1J (for example, the organic fiber assembly 1). At theend-winding step, the continuous sheet-shaped fiber assembly 1J is woundup on the reel 1311, and when the number of times R of winding reachesthe number corresponding to the thickness t/2 which is a half of thenecessary predetermined thickness t of the core material 5, therotations of the original fabric roll 1301 and the reel 1311 halt. Thecutting step is a step for cutting the continuous sheet-shaped fiberassembly 1J at a predetermined position, which is a step for separatingthe original fabric roll 1301 from the reel 1311 by cutting thecontinuous sheet-shaped fiber assembly 1J at the predetermined cutposition between the original fabric roll 1301 and the reel 1311 whilebeing clamped at the front and back of the predetermined cut part.

Here, the substantially cylindrical continuous sheet-shaped fiberassembly 1J wound up on the reel 1311 is clamped and retained by theclamp members 1320 (the clamp members 1320 c and 1320 d) (refer to (d)of FIG. 9). At this time, in order not to disperse an end-winding endportion 1Je which is cut (the cut end face) of the continuoussheet-shaped fiber assembly 1J wound on the reel 1311, or in order toarrange the end-winding end portion 1Je (the cut end face) at thefolding end portion 5 f (namely, not to arrange at the flat part 5 g)when the core material 5 is formed as shown in FIG. 5, it is preferableto cut the continuous sheet-shaped fiber assembly 1J at the position inthe back of the position at which the continuous sheet-shaped fiberassembly 1J is clamped by the clamp member 1320 (for example, atdirectly after the clamped position).

(d) of FIG. 9 is a core material fixing step for clamping thesubstantially cylindrical continuous sheet-shaped fiber assembly 1J (forexample, the organic fiber assembly 1) by the clamp member 1320. At thecutting step, the continuous sheet-shaped fiber assembly 1J is cut.Then, the clamp member 1320 is inserted into the clamp member settingpart 1313 (the clamp member setting parts 1313 c and 1313 d) such as aconcave part or a notch, etc. provided at the reel 1311. Theneighborhood of the end-winding end portion 1Je (the cut end face) isclamped so as not to disperse or detach the end-winding end portion 1Je(the cut end face) of the continuous sheet-shaped fiber assembly 1J.

(e) of FIG. 9 is a reel deforming step for releasing the tensional forceof the continuous sheet-shaped fiber assembly 1J wound up on the reel1311 by moving/deforming at least one circumferential member (1312 a,1312 b), out of a plurality of circumferential members (1312 a to 1312d) provided at the reel 1311 in the circumferential direction, in theradial center direction. At the core material fixing step, theneighborhood of the end-winding end portion 1Je (the cut end face) isclamped. At the reel deforming step, while the continuous sheet-shapedfiber assembly 1J is wound up on the reel 1311 at the number of times Rcorresponding to the predetermined thickness (t/2) and is clamped by theclamp member 1320 (the clamp members 1320 c and 1320 d), at least onecircumferential member (in the present embodiment, two circumferentialmembers 1312 a and 1312 b facing in the radial direction) out of theplurality of circumferential members 1312 (the circumferential member1312 a to 1312 d) of the reel 1311 is moved in the contracting directiontoward the center side of radial direction of the reel 1311. That is,after the continuous sheet-shaped fiber assembly 1J is wound up on thereel 1311, the circumferential member retaining shafts 1316 a and 1316 bare moved in the contracting direction toward the center side of radialdirection, thereby also moving the circumferential members 1312 a and1312 b in the contracting direction toward the center side of radialdirection.

Therefore, the circumferential members 1312 a and 1312 b are moved inthe contracting direction toward the center side of radial direction,thereby releasing the tensional force of the continuous sheet-shapedfiber assembly 1J wound substantially cylindrically on the reel 1311with the predetermined tensional force. The continuous sheet-shapedfiber assembly 1J wound substantially cylindrically can be easily takenoff from the reel 1311 (the continuous sheet-shaped fiber assembly 1Jclamped from the shaft core direction of the rotating shaft 1315 of thereel 1311 can be easily taken off). That is, the tensional force of thecontinuous sheet-shaped fiber assembly 1J (for example, the organicfiber assembly 1) which is wound on the reel 1311 with the predeterminedtensional force is released, thereby easily taking off from the reel1311 the continuous sheet-shaped fiber assembly 1J wound on the reel1311.

(f) of FIG. 9 is a reel separating step for separating the reel from thesubstantially cylindrical continuous sheet-shaped fiber assembly 1J bytaking off the reel 1311 from the continuous sheet-shaped fiber assembly1J wound up on the reel 1311. At the reel deforming step, at least onecircumferential member 1312 (the circumferential members 1312 a and 1312b) of the reel 1311 is moved/deformed in the center side of radialdirection, thereby releasing the tensional force caused by the windingof the continuous sheet-shaped fiber assembly 1J wound on the reel 1311.At the reel separating step, the substantially cylindrical continuoussheet-shaped fiber assembly 1J of which the tensional force is releasedis taken off from the reel 1311 in the shaft center direction of therotating shaft 1315. In another way, the reel 1311 also can be taken offfrom the substantially cylindrical continuous sheet-shaped fiberassembly 1J while being clamped.

(g) of FIG. 9 is a core material forming step for forming the flat corematerial 5 by pulling the substantially cylindrical continuoussheet-shaped fiber assembly 1J removed from the reel 1311 with the clampmembers 1320 (the clamp members 1320 c and 1320 d) which are formingmembers in the substantially opposite directions (inverse directions).At the reel separating step, the continuous sheet-shaped fiber assembly1J is separated from the reel 1311 while being clamped by the clampmembers 1320 which are the forming members. At the core material formingstep, the substantially cylindrical continuous sheet-shaped fiberassembly 1J, taken off from the reel 1311 while being clamped by the twoclamp members 1320 c and 1320 d, is pulled by the two clamp members 1320c and 1320 d to the opposite sides of the substantially straight linedirection, that is, pulled in the inverse directions. The substantiallycylindrical continuous sheet-shaped fiber assembly 1J is folded at thepositions clamped by the clamp members 1320 which are the formingmembers, thereby forming the flat (sheet-shaped) core material 5 havingthe folding end portions 5 f and the flat part 1311 g. The core material5 structured by the continuous sheet-shaped fiber assembly 1J formed ina flat plate shape by the clamp members 1320 which are the formingmembers is transferred to a conveyer 1400 while being clamped by the twoclamp members 1320 at the folding end portions 5 f. Then, the corematerial 5 is formed by removing the clamp members 1320. That is, thecontinuous sheet-shaped fiber assembly 1J (for example, the organicfiber assembly 1) made by continuous fiber (for example, the organicfiber 2) and continuously flat (sheet-shaped) is wound continuously fromthe inside toward the outside, the flat core material 5 is formed andproduced, and moved on the conveyer 1400.

(h) of FIG. 9 is a vacuum heat insulating material manufacturing stepfor manufacturing the vacuum heat insulating material 7 by inserting thecore material 5 formed on the conveyer 1400 into a gas-barrier outercover material 4, which has an opening part 4 a at one end,decompressing the inside and sealing substantially hermetically. Thecore material 5, which is made by laminating a plurality of layers ofthe continuous sheet-shaped fiber assembly 1J and winding upcontinuously from the inside toward the outside to form in a flat plateshape, is inserted into the gas-barrier outer cover material 4 at leastone end of which has the opening part 4 a. The core material 5 insertedin the gas-barrier outer cover material 4 is carried into a vacuumfurnace. A sealing part (for example, the opening part 4 a) of the outercover material 4 is heat-sealed in a substantially vacuum state, and thevacuum heat insulating material 7 is completed.

Here, since the circumferential member 1312 of the reel 1311 forms asubstantially continuous cylindrical shape in the winding direction (ina circumferential direction, a rotational direction), the tensionalforce caused by the winding when the continuous sheet-shaped fiberassembly 1J is wound up on the reel 1311 becomes substantially uniformin the winding direction (in the circumferential direction), and at thetime of winding, there occurs no damage nor cut off on the continuoussheet-shaped fiber assembly 1J, thereby obtaining the core material 5and the vacuum heat insulating material 7 with high reliability.

In the present embodiment, although the circumferential member 1312which forms the substantially continuous cylindrical shape in thewinding direction (in the circumferential direction) is used for thereel 1311, the shape is not necessarily the substantially cylindricalshape, but can be polygonal (octagonal, hexagonal, flat-plate shaped,etc.).

FIG. 10 shows the first embodiment and is a pattern diagram showinganother reel. In FIG. 10, (a) shows an example of an octagonal reel, and(b) shows a state in which the continuous sheet-shaped fiber assembly 1Jis wound up on the octagonal reel. As shown in the figure, thecircumferential member 1312 is not necessarily continuous in the windingdirection (in the circumferential direction). In FIG. 10, the reel 1311is provided with rod-shaped (for example, a prism or a column)circumferential members 1312 in the circumferential direction at eightpositions with a substantially equal interval, and the reel 1311 rotatesaround the rotating shaft 1315, thereby winding up the continuoussheet-shaped fiber assembly 1J from the original fabric roll 1301. Asshown in FIG. 10, for example, when a plurality of (for example, eight)circumferential members 1312 are not continuous in the windingdirection, it becomes possible to clamp the continuous sheet-shapedfiber assembly 1J which is wound up on the reel 1311 by inserting theclamp member 1320 (refer to FIG. 8, not shown in FIG. 10) between theplurality of circumferential members 1312 (space between thecircumferential member 1312 and the circumferential member 1312) whichare prismatic or columnar, etc. provided with substantially equalintervals in the winding direction. The clamp member setting part 1313is unnecessary, and thereby the light, simple-structured, and low-costreel 1311 can be obtained.

In the present embodiment, the original fabric roll 1301 of the longfibered non-woven cloth obtained by continuously winding up on thesubstantially cylindrical original fabric roller 1302 the continuoussheet-shaped fiber assembly 1J made by the continuous organic fiber 2,and the reel 1311 having the predetermined width, which is providedseparately with the original fabric roll 1301, for winding up thecontinuous sheet-shaped fiber assembly 1J of the long fibered non-wovencloth of the original fabric roll 1301 are provided. The continuoussheet-shaped fiber assembly 1J (for example, the organic fiber assembly1), wound on the original fabric roller 1302, is wound on the reel 1311at the predetermined number of times R (corresponding to the thicknesst/2 which is a half of the necessary predetermined thickness t of thecore material 5). The continuous sheet-shaped fiber assembly 1J islaminated with the necessary predetermined thickness t of the corematerial 5. Thus it is not necessary to laminate the non-woven clothsheet (fiber assembly) which is cut into the predetermined size (thewidth or the length) sheet by sheet, and the core material 5 can besimply manufactured by inexpensive manufacturing equipment with a lowcost.

That is, the core material 5 is formed in a flat plate shape by windingup the continuous sheet-shaped fiber assembly 1J (for example, theorganic fiber assembly 1) formed by continuous fiber (for example, theorganic fiber 2) continuously from the inside toward the outside. Out offour end faces of the core material 5, which is substantiallyrectangular and flat-plate-shaped, end portions in the length direction(the folding end portion 5 f) are formed by folding (bending) thecontinuous sheet. Since the two folding end portions 5 f to which thefolding processing is done (bending processing) are not the portionswhere the end faces thereof are cut off, the organic fiber 2 is notprotruded from the folding end portions 5 f, and cutting the end facesis unnecessary since the end faces are not ragged. Further, the cuttingpart (region) is reduced, thereby obtaining the core material 5 andvacuum heat insulating material 7 which can be easily processed with alow cost. Further, when the original fabric roll 1301 is used by cuttinginto the necessary predetermined width, out of four end faces of thesubstantially rectangular flat core material 5, two end faces in thewidth direction correspond to the end faces in the width direction ofthe core material 5. That is, the two end faces of the core material 5in the width direction have been previously cut into the predeterminedwidth in the form of the original fabric roll 1301. The cutting afterforming as the core material 5 is unnecessary, and thus themanufacturing line of the core material 5 is simplified, therebyobtaining the core material 5 and vacuum heat insulating material 7 witha low cost.

Further, since the fiber does not protrude from the end face of the corematerial 5, or the end face is not ragged, it becomes unnecessary to cutthe end face. Further, it is possible to avoid damaging sealability ofthe sealing part of the outer cover material 4 caused by the protrusionof the remaining fiber from the cut end face which may occur when thefiber length of the remaining fiber is shortened by cutting the endface.

Further, as shown in FIG. 24, when the core material 5, 550, or 560laminated by continuously winding up from the inside toward the outsideto form in a flat plate shape is used for the vacuum heat insulatingmaterial 7, 750, or 760, a shape of the cross section in the lengthdirection (a cross section at right angles to the width direction) ofthe end portion in the length direction (the folding end portion 5 f) ofthe core material 5 becomes substantially triangular. FIG. 24 shows thefirst embodiment and is a pattern diagram showing a shape of the vacuumheat insulating material. (a) of FIG. 24 is a view of the cross sectionin the length direction (a cross section at right angles to the widthdirection) of the vacuum heat insulating material 7, 750, or 750, and(b) of FIG. 24 is a main part front view of the end portion in thelength direction of the vacuum heat insulating material 7, 750, or 760which is viewed from the direction at right angles to the lengthdirection.

In FIG. 24, when the core material 5 laminated by continuously windingup from the inside toward the outside to form in a flat plate shape isused for the vacuum heat insulating material 7, 750, or 760, the vacuumheat insulating material is constituted by a flat smooth part Lg (a partof a length L1) and both end portions Lf (parts of a length L2) having asubstantially triangular cross section in the length direction. At thistime, the both end portions (the folding end portions 5 f) of the corematerial 5 in the length direction are inserted into the outer covermaterial 4, and the outer cover material 4 is decompressed and sealed inthat state. The cross sectional shape (the cross sectional shape beingat right angles (vertical) to the width direction) of the both endportions Lf in the length direction, of which the thickness is graduallyreduced toward the outside direction with respect to the lengthdirection, that is, the cross sectional shape in the length direction(the cross sectional shape being at right angles (vertical) to the widthdirection) becomes a substantially triangular shape. Thus the outercover material 4 is hardly shrunk, or hardly broken, thereby obtainingthe highly reliable vacuum heat insulating material. Namely, the vacuumheat insulating material includes the core material 5 of the laminatedstructure formed in a flat plate shape by winding up the sheet-shapedfiber assembly which has the predetermined width and is continuous inthe length direction from the inside toward the outside; and thegas-barrier outer cover material 4 which contains the core material 5inserted from the opening part 4 a to the inside, and while the insideis decompressed, the opening part 4 a is sealed. The vacuum heatinsulting material is obtained, of which, while the core material 5 isdecompressed in the outer cover material 4, the cross sectional shapebeing at right angles to the width direction of the end portions in thelength direction of the core material 5 (the folding end portions 5 fwhich are both end portions in the length direction) is thesubstantially triangular shape, in which the thickness is graduallyreduced toward the outside in the length direction. Further, when onevacuum heat insulating material 7, 750, or 760 is processed by foldingto be cylindrical, when the end faces in the length direction are facedwith each other to use connectedly, when the end faces of a plurality ofvacuum heat insulating materials 7, 750, or 760, the number of which istwo or over, are faced to use, slope face parts (slope face part Lfs ofFIG. 24) of the substantially triangular end face of the plurality ofvacuum heat insulating materials 7, 750, or 760 are connected so as tobe contacted each other. It is possible to reduce a jointing thicknessof contacting parts, further to decrease heat leakage from thecontacting parts, thereby obtaining the vacuum heat insulating material7, 750, or 760 with high performance, and equipment such as therefrigerator, etc. which mounts the vacuum heat insulating material 7,750, or 760.

(Laminating Method of Fiber Assembly, Manufacturing Method 3 of CoreMaterial)

Next, a manufacturing method of the core material 5 by combining aplurality of original fabric rolls 1301 will be explained. FIGS. 11through 14 show the first embodiment. FIG. 11 is a diagram showing astructure of a combined original fabric roll having a large width madeby combining a plurality of the original fabric rolls. FIG. 12 is apattern diagram showing a structure of a winding device when the windingdevice uses two combined original fabric rolls for winding up on a reel.FIG. 13 is a pattern diagram showing a structure of the organic fiberassembly wound up by the winding device using two combined originalfabric rolls (the upper side original fabric roll and the lower sideoriginal fabric roll). FIG. 14 is a cross sectional view of the corematerial wound up by the winding device using two combined originalfabric rolls.

For example, a plurality of original fabric rolls (for example, a mainbody part A 1301 a, a main body part B 1301 b, a main body part C 1301c, a main body part D 1301 d) being wound up at substantially the samenumber of windings (the same number of laminated sheets) should becombined so as to be next to each other (without a gap, preferably; apredetermined gap may be provided as will be discussed later if the gapis necessary) in the width direction (the lateral direction), and thefirst original fabric roll 1305 (the upper side roll) having thepredetermined width is produced. Further, similar to the first originalfabric roll 1305, a plurality of original fabric rolls (for example, amain body part E 1301 e, a main body part F 1301 f, a main body part G1301 g, a main body part H 1301 h, all not shown) being wound up atsubstantially the same number of windings (the same number of laminatedsheets) should be combined so as to be next to each other (without agap, preferably; a predetermined gap may be provided) in the widthdirection (the lateral direction), and the second original fabric roll1306 (the lower side roll) having the predetermined width is produced.

Here, the widths of a plurality of original fabric rolls (for example,the main body part A 1301 a, the main body part B 1301 b, the main bodypart C 1301 c, and the main body part D 1301 d) can be the same ordifferent. In the same manner, the widths of a plurality of originalfabric rolls (for example, the main body part E 1301 e, the main bodypart F 1301 f, the main body part G 1301 g, the main body part H 1301 h,all not shown) can be the same or different. The number of the pluralityof original fabric rolls used for the first original fabric roll 1305and the number of the plurality of original fabric rolls used for thesecond original fabric roll 1306 can be the same or different.

As for both of the first original fabric roll 1305 and the secondoriginal fabric roll 1306, the plurality of original fabric rolls (forexample, the plurality of main body parts) are aligned in the widthdirection so as to be next to each other. There exists a gap (a minutegap, a predetermined gap) between the neighboring main body parts (forexample, the main body part A 1301 a and the main body part B 1301 b,etc.), and the neighboring main body parts (for example, the main bodypart A 1301 a and the main body part B 1301 b, etc.) are not continuousbut discontinuous; that is, there exists a slit portion (for example, aslit portion A between the main body part A 1301 a and the main bodypart B 1301 b, a slit portion B between the main body part B 1301 b andthe main body part C 1301 c, a slit portion C between the main body partC 1301 c and the main body part D 1301 d, etc.). Further, in the presentembodiment, at least one of the first original fabric roll 1305 and thesecond original fabric roll 1306 includes an ear part original fabricroll having an ear part with a ragged ridge line which is generated atthe time of cutting the original fabric roll material into thepredetermined width is used for the original fabric roll (for example,the main body part A 1301 a or the main body part D 1301 d, the mainbody part E 1301 e or the main body part H 1301 h, etc.) arranged at theend side in the width direction of the plurality of original fabricrolls (refer to FIG. 11).

In the present embodiment, the number of the plurality of originalfabric rolls (four including the main body part A 1301 a, the main bodypart B 1301 b, the main body part C 1301 c, and the main body part D1301 d) used for the first original fabric roll 1305 is made the same asthe number of the plurality of original fabric rolls (four including themain body part E 1301 e, the main body part F 1301 f, the main body partG 1301 g, and the main body part H 1301 h) used for the second originalfabric roll 306. Further, the plurality of original fabric rolls (themain body part A 1301 a, the main body part B 1301 b, the main body partC 1301 c, and the main body part D 1301 d) used for the first originalfabric roll 1305 and a plurality of original fabric rolls (the main bodypart E 1301 e, the main body part F 1301 f, the main body part G 1301 g,and the main body part H 1301 h) used for the second original fabricroll 1306 are arranged while being displaced in the width direction by apredetermined amount Xb (refer to FIG. 14). The first (organic) fiberassembly 1K wound on the first original fabric roll 1305 and the second(organic) fiber assembly 1H wound on the second original fabric roll1306 are wound up together on the reel 1311 so as to be overlappedvertically (at substantially right angles to the sheet face) while beingdisplaced in the width direction of the sheet face by the predeterminedamount Xb. For example, the first (organic) fiber assembly 1K can be theorganic fiber assembly, or can be another fiber assembly (for example,the inorganic fiber assembly). The same can be said for the second(organic) fiber assembly 1H. At this time, the first original fabricroll 1305 and the second original fabric roll 1306 are arranged in thelongitudinal direction, the vertical direction, or the oblique directionwith respect to the moving direction (winding up direction)) of thefirst (organic) fiber assembly 1K and the second (organic) fiberassembly 1H. The widths of the plurality of original fabric rolls of thesecond original fabric roll 1306 corresponding to the plurality oforiginal fabric rolls of the first original fabric roll 1305 are madesubstantially the same and arranged while being displaced by thepredetermined amount Xb.

That is, the widths of respective original fabric rolls (for example,the main body part A 1301 a) which constitute the first original fabricroll 1305 and respective original fabric rolls (for example, the mainbody part E 1301 e) which constitute the second original fabric roll1306 arranged in the back of (or below, etc.) the first original fabricroll 1305 are made substantially the same. In the same manner, therespective original fabric rolls (the main body part B 1301 b and themain body part F 1301 f, the main body part C 1301 c and the main bodypart G 1301 g, the main body part D 1301 d and the main body part H 1301h) are set to have substantially the same width. However, thepredetermined width of the first original fabric roll 1305 (the upperroll) is preferably the same with the predetermined width of the secondoriginal fabric roll 1306 (the lower side roll).

Further, in the present embodiment, as shown in FIG. 12, as for thearrangement of the first original fabric roll 1305 (the upper side roll)and the second original fabric roll 1306 (the lower side roll) of themanufacturing apparatus of the core material, the first original fabricroll 1305 (the upper roll) is arranged in the backward side (or theupper side or the upper oblique side, etc.) to the second originalfabric roll 1306 (the lower side roll) in the direction of the reel 1311(the feeding direction of the continuous sheet-shaped fiber assembly1J). That is, toward the direction of the reel 1311, the second originalfabric roll 1306 (the lower side roll) and the first original fabricroll 1305 (the upper side roll) are arranged in order. At this time, thefirst (organic) fiber assembly 1K wound on the first original fabricroll 1305 (the upper side roll) is arranged at the upper side to thesecond (organic) fiber assembly 1H wound on the second original fabricroll 1306 (the lower side roll). Since they are wound up on the reel1311, the first (organic) fiber assembly 1K wound on the first originalfabric roll 1305 (the upper side roll) is wound up so that the first(organic) fiber assembly 1K should be always located outside the second(organic) fiber assembly 1H wound on the second original fabric roll1306 (the lower side roll) in the radial direction of the reel 1311.Here, the first original fabric roll 1305 (the upper side roll) and thesecond original fabric roll 1306 (the lower side roll) are arranged sothat the first (organic) fiber assembly 1K and the second (organic)fiber assembly 1H are vertically overlapped and wound up on the reel1311.

Here, when a predetermined width which is necessary for the product issmall (for example, around 100 mm or 200 mm), it is easy to manufacturethe original fabric roll (the first original fabric roll 1305 (the upperside roll), the second original fabric roll 1306 (the lower side roll),etc.), since the manufacturing does not require a large space. On thecontrary, when a predetermined width which is necessary for the productis large (for example, 1100 mm or 2000 mm, etc.), it becomes difficultto manufacture the original fabric roll (the first original fabric roll1305 (the upper side roll), the second original fabric roll 1306 (thelower side roll), etc.). Further, some product requires the vacuum heatinsulating material 7 having different width. In such a case, if it isdealt with only one original fabric roll, a number, which corresponds tothe number of necessary predetermined widths, of the original fabricrolls is required. Not only manufacturing the original fabric rolls isdifficult, but also the number of types of the original fabric rolls isincreased, which increases the manufacturing cost. Therefore, in thepresent embodiment, a plurality of original fabric rolls are combined soas to be next to each other in the width direction, and used as thecombined roll (for example, the first original fabric roll 1305 or thesecond original fabric roll 1306).

Like the present embodiment, if the original fabric rolls (for example,the main body part A 1301 a, the main body part B 1301 b, the main bodypart C 1301 c, and the main body part D 1301 d) having a plurality ofwidths (different widths) are arranged so as to be next to each other inthe width direction to form one original fabric roll (for example, thefirst original fabric roll 1305) having the large width for use, thewidth of respective original fabric rolls can be small. It is possibleto easily manufacture the original fabric roll (for example, the mainbody part A 1301 a and the main body part B 1301 b, etc.) without muchconsidering about the manufacturing place. Moreover, when the originalfabric roll having a large width is required, one original fabric rollhaving the large width (for example, the first original fabric roll1305, the second original fabric roll 1306, etc.) can be produced bycombining a plurality of original fabric rolls having the small width.Thus, the manufacturing place of the original fabric roll can beanywhere, and the number of types of the original fabric rolls can bereduced, thereby obtaining the core material 5 and the vacuum heatinsulating material 7 having a large degree of freedom with a low cost.For example, one original fabric roll having the large width can beproduced by combining a plurality of original fabric rolls withdifferent widths (the main body part A 1301 a, the main body part B 1301b, etc.), or by combining a plurality of small original fabric rollswith the substantially same widths (for example, one original fabricroll with the same width such as the main body part B 1301 b, etc.).

Further, in the present embodiment, the first (organic) fiber assembly1K wound on the first original fabric roll 1305 (the upper roll) whichis the combined original fabric roll constituted by the plurality oforiginal fabric rolls (for example, the main body part A 1301 a, themain body part B 1301 b, the main body part C 1301 c, and the main bodypart D 1301 d) and the second (organic) fiber assembly 1H wound on thesecond original fabric roll 1306 (the lower roll) which is the combinedoriginal fabric roll constituted by the plurality of original fabricrolls (for example, the main body part E 1301 e, the main body part F1301 f, the main body part G 1301 g, and the main body part H 1301 h)are arranged while being displaced by predetermined amount Xb (forexample, around 5 mm to 40 mm, preferably 10 mm to 20 mm) in the widthdirection (the lateral direction) because of the following.

(1) For example, out of the plurality of original fabric rolls (the mainbody part A 1301 a, the main body part B 1301 b, the main body part C1301 c, and the main body part D 1301 d) which constitute the firstoriginal fabric roll 1305, in the connecting region of the originalfabric rolls (for example, the main body part A 1301 a, the main bodypart B 1301 b, etc.) which are located next to each other in the widthdirection, there actually exists a slight gap or even if there exists nogap, the neighboring region includes a slit portion (for example, a slitportion A between the main body part of A and the main body part of B)and is not continuous. If the plurality of sheets of the first (organic)fiber assembly 1 and the second (organic) fiber assembly 1H arelaminated without being displaced by the predetermined amount Xb, theslit portions (a connecting part, a neighboring part) are located in thesubstantially same position, and thus the lamination may be divided bythe slit portions. That is, since the lamination is not continuous atthe slit portion (the connecting part, the neighboring part) and may bebended or broken at the slit portion, bending strength which isnecessary for the core material 5 cannot be obtained. The lamination isnot continuous but slit at the slit portion (the neighboring part), andthe lamination may be torn to cause to break the outer cover material 4and so on, which prevents obtaining the core material 5 with thenecessary width, and further the performance of the vacuum heatinsulating material 7. In the present embodiment, the plurality oflayers of the first original fabric roll 1305 and the second originalfabric roll 1306 are laminated so that the second original fabric roll1306 (the lower roll) is displaced with respect to the first originalfabric roll 1305 (the upper roll) by the predetermined amount Xb. Thus,the lamination is not torn or divided by friction, etc. generated at thedisplaced part of the predetermined amount Xb at the slit portion (aneighboring region), thereby obtaining the core material 5 of thenecessary predetermined size having the necessary heat insulatingperformance.

(2) Although the first original fabric roll 1305 (the upper roll) andthe second original fabric roll 1306 (the lower roll) are lapped whilebeing displaced by the predetermined amount Xb at the neighboringregion, because the slit portion (the neighboring region) exists, thefirst (organic) fiber assembly 1K and the second (organic) fiberassembly 1H are not continuous on the same plane. Therefore, the slitportion is easily bendable. In the conventional vacuum heat insulatingmaterial, a specific processing is provided to implement a concavegroove formation, etc. for folding, which increases the manufacturingcost. On the contrary, in the present embodiment, the neighboring region(the slit portion) is form to be easily foldable in the manufacturingprocess, and the easily foldable region is effectively used by arrangingat a region which is necessary to be folded. For example, in case of arefrigerator, it is considered that the vacuum heat insulating material7 is provided by bridging between a rear face wall and a top face wall,etc. which are arranged with a predetermined angle (substantially 90degrees, for example). In such a case, a large vacuum heat insulatingmaterial 7 is necessary, and moreover, the vacuum heat insulatingmaterial 7 needs to be foldable. Therefore, a large facility formanufacturing the original fabric roll material is necessary, whichlimits the manufacturing place, and the manufacturing is difficult. Thespecific processing for folding is necessary, which increases the cost,and the dealing is difficult. As for the vacuum heat insulating material7 of the present embodiment, it is possible to use a plurality oforiginal fabric rolls as one large original fabric roll by arranging theplurality of original fabric rolls so as to be next to each other in thewidth direction, and moreover, it is sufficient to arrange the slitportion (the neighboring part) at a region which is necessary to befolded. The width of the original fabric roll can be selected freely bycombining the original fabric rolls having the small width, and further,the specific processing to folding is unnecessary. Further, the corematerial 5 having a large width can be produced by combining a pluralityof original fabric rolls having a small width. Thus, it becomes possibleto dispose the vacuum heat insulating material 7 to the walls arrangedwith the predetermined angle of the refrigerator, etc. by bridging thewalls to which it has been difficult to dispose the vacuum heatinsulating material conventionally.

(3) End portions of both sides in the width direction of the originalfabric roll material before cutting both ends in the width direction arecalled as ear parts, in which sufficient amount of fiber of the organicfiber assembly 1 or the continuous sheet-shaped fiber assembly 1J maynot exist for the necessary thickness, the thickness may be uneven, andthe ridge line of the end face in the width direction may be ragged.When used as the original fabric roll, the both sides of the originalfabric roll material are previously cut off into the necessarypredetermined width for using as the original fabric roll. Therefore, anear part original fabric roll which has been cut off from the ear partof the both sides in the width direction of the original fabric rollmaterial has weak strength and a ragged end face (the ridge line), whichhas been disposed of conventionally. In the present embodiment, the earpart original fabric roll which has been conventionally disposed of (inthe present embodiment, for example, it corresponds to the main bodypart A 1301 a or the main body part D 1301 d) is used for the originalfabric roll (for example, the main body part A 1301 a or the main bodypart D 1301 d, etc.) used for the both sides in the width directionamong the plurality of original fabric rolls which constitute the firstoriginal fabric roll 1305 or the second original fabric roll 1306 asshown in FIG. 11. Since the plurality of layers of the first originalfabric roll 1305 and the second original fabric roll 1306 are laminatedwhile being displaced by the predetermined amount Xb, the ear part andthe part which is not the ear part are alternatively laminated,positions of the ear parts are arranged while being displaced, and theear parts are never laminated consecutively. Accordingly, even if theear part original fabric roll is used, the strength necessary for thecore material 5 can be obtained.

Here, as shown in FIG. 11, in the first original fabric roll 1305, themain body part A 1301 a, the main body part B 1301 b, the main body partC 1301 c, and the main body part D 1301 d are arranged so as to be nextto each other in the width direction. Here, the widths of the main bodypart A 1301 a, the main body part B 1301 b, the main body part C 1301 c,and the main body part D 1301 d are respectively T1, T2, T3, and T4, andthe width of the first original fabric roll 1305 becomes TA(TA=T1+T2+T3+T4). Therefore, the width of respective original fabricrolls (T1, T2, T3, and T4) of the first original fabric roll 1305 can bedecided according to the predetermined width necessary for the product.In the same manner, the widths of respective original fabric rolls ofthe second original fabric roll 1306 can be decided. That is, the widthsof the main body part A 1301 a, the main body part B 1301 b, the mainbody part C 1301 c, and the main body part D 1301 d (the widths of themain body part E 1301 e, the main body part F 1301 f, the main body partG 1301 g, and the main body part H 1301 h) can be decided. At this time,the widths T1, T2, T3, and T4 can be the same or different.

Therefore, the widths of the plurality of original fabric rolls (forexample, the main body part A 1301 a, the main body part B 1301 b, themain body part C 1301 c, the main body part D 1301 d, the main body partE 1301 e, the main body part F 1301 f, the main body part G 1301 g, andthe main body part H 1301 h) can be appropriately selected respectively,and the degree of freedom of designing is increased, thereby obtainingthe low-cost core material 5, the vacuum heat insulating material 7, andthe equipment such as the refrigerator, etc. Further, since the corematerial 5 is manufactured by winding up the first original fabric roll1305 and the second original fabric roll 1306 on the reel 1311 whilebeing displaced by the predetermined amount Xb, the folding can beeasily done at the slit portion. Thus, it is easy to manufacture thefoldable vacuum heat insulating material 7 without specific processing,etc., and it is easy to provide the vacuum heat insulating material 7 atthe heat insulating wall of the equipment such as a refrigerator, etc.having the heat insulating wall face which is curved with apredetermined angle. The coverage of the vacuum heat insulating material7 can be increased, and the vacuum heat insulating material and theequipment with a high performance and a low cost can be obtained.

As shown in FIG. 13, when the continuous sheet-shaped fiber assembly 1Jis wound up on the reel 1311, the first (organic) fiber assembly 1K (thefirst (organic) fiber assemblies 1Ka to 1Kd, the upper side organicfiber assembly) from the first original fabric roll 1305 (the upper sideroll) and the second (organic) fiber assembly 1H (the second (organic)fiber assemblies 1Ha to 1 hd, the lower side the organic fiber assembly)from the second original fabric roll 1306 (the lower side roll) arewound up on the reel 1311 while being displaced by the predeterminedamount Xb. At the cross section vertical to the winding direction, thefirst (organic) fiber assembly 1K and the second (organic) fiberassembly 1H wound on the reel 1311 are alternatively laminated whilebeing displaced by the predetermined amount Xb as shown in FIG. 14. Thelamination is done by winding up continuously from the inside toward theoutside. Therefore, since the first (organic) fiber assembly 1K and thesecond (organic) fiber assembly 1H are displaced by the predeterminedamount Xb, the distance between the first slit portion 57 (the upperside slit portion) of the first (organic) fiber assembly 1K (the upperside organic fiber assembly) and the second slit portion 58 (the lowerside slit portion) of the second (organic) fiber assembly 1H (the lowerside the organic fiber assembly) corresponds to the displaced amount Xb.The first (organic) fiber assembly 1K and the second (organic) fiberassembly 1H are overlapped and laminated with the amount of Xb. Thus, itis difficult to separate the first (organic) fiber assembly 1K from thesecond (organic) fiber assembly 1H because of friction, etc.

Here, the core material 5 made by laminating the plurality of layers ofthe organic fiber assembly 1 (the continuous sheet-shaped fiber assembly1J, the first (organic) fiber assembly 1K, and the second (organic)fiber assembly 1H) becomes harder to be folded, as the thickness tbecomes thicker in the vacuum state (in the decompressed state).However, in the present embodiment, since there exist two slit portions(the first slit portion 57 and the second slit portion 58) at positionswith the distance of the predetermined amount Xb, it is possible toeasily fold (obtain a predetermined folding angle) the core material 5by folding with two steps at the two slit portions (the first slitportion 57 and the second slit portion 58) even if the thickness becomesthick.

In the present embodiment, a lapping area Xb is decided according to thethickness of the core material 5. That is, when the thickness of thecore material 5 is small, the predetermined amount Xb can be small; onthe contrary, when the thickness of the core material 5 is large, thecore material 5 becomes hard to be folded, and thus the predeterminedamount Xb is made appropriately large correspondingly. Here, when thepredetermined amount Xb is too small, the overlapping length (thelapping area) becomes too short to obtain the frictional force. Thus,the first (organic) fiber assembly 1K and the second (organic) fiberassembly 1H may be separated at the lapped part (between the main bodyparts), which prevents obtaining the core material 5 with thepredetermined width. In the present embodiment, the lapping area Xb ismade at least 7 mm (preferably at least 10 mm). When the lapping area is5 mm, since the lapping area is too short to obtain necessary frictionalforce. The respective organic fiber assemblies (the first (organic)fiber assemblies 1Ka to 1Kd of the first (organic) fiber assembly 1K, orthe second (organic) fiber assemblies 1Ha to 1Hd of the second (organic)fiber assembly 1H) are separated at the slit portions, and thus the corematerial 5 having the predetermined width cannot be obtained. Here, whenthe lapping area Xb is at least 10 mm, even if the ear part is used forthe lapping part, the frictional force can be stably obtained, andmoreover, it is found that the reduction of the heat conductivity can besuppressed to small.

Further, the larger the lapping area Xb becomes, the larger thenecessary frictional force can be obtained, which is preferable for thecore material 5 since the reliability is improved. However, when thelapping area Xb is too large with respect to the thickness of the vacuumheat insulating material 7, the distance between the two slit portionsat the time of folding becomes large, and the folding becomes harder.When the vacuum heat insulating material 7 is folded, it is preferablethat the lapping area Xb should be no more than around three times ofthe thickness of the vacuum heat insulating material 7 (for example,when the thickness t of the vacuum heat insulating material is 10 mm, itis preferable the lapping area Xb should be no more than around 30 mm).

FIG. 15 shows the first embodiment and is a perspective view of a corematerial 550 when the core material 550 is produced by winding up on thereel the combined original fabric roll made by combining three originalfabric rolls. In FIG. 15, in the core material 550, in the same mannerto the core material 5 shown in FIG. 11 to FIG. 14, the first (organic)fiber assembly 1K (the first (organic) fiber assemblies 1Ka, 1Kb, and1Kd) (the upper side organic fiber assembly) from the first originalfabric roll 1305 (the upper side roll) and the second (organic) fiberassembly 1H (the second (organic) fiber assemblies 1Ha, 1Hb, and 1Hd)(the lower side organic fiber assembly) from the second original fabricroll 1306 (the lower side roll) are laminated by winding up on the reel1311 continuously from the inside toward the outside while beingdisplaced by the predetermined amount Xb. Then, the lamination isclamped at two positions by the two clamp members 1320, and folded atthe clamped parts, thereby producing the flat core material 550. Here,in FIG. 15, signs other than the ones shown in the figure are omitted. Avacuum heat insulating material 702 (not shown) is manufactured by usingthe core material 550.

The core material 550 is constituted by two folding parts 551 f (foldingend portions) folded (bended) by the clamp members 1320 and a flat part551 g (a smooth part) provided between the two folding parts 551 f.Further, the neighboring part of the respective first (organic) fiberassemblies 1Ka, 1Kb, and 1Kd of the first (organic) fiber assembly 1K(the upper side organic fiber assembly) is the first slit portion 57(the upper side slit portion) shown in FIG. 14, and the neighboring partof the respective second (organic) fiber assemblies 1Ha, 1Hb, and 1Hd ofthe second (organic) fiber assembly 1H (the lower side organic fiberassembly) is the second slit portion 58 (the lower side slit portion).The distance (the length) between the first slit portion 57 and thesecond slit portion 58 in the width direction corresponds to thedisplaced amount Xb. Therefore, the folding processing can be easilyimplemented using the first slit portion 57 and the second slit portion58.

Here, in FIG. 15, the end-winding end portion 551Je is arranged abovethe flat part 551 g; however, it is preferable to arrange in theneighborhood of the folding part 551 f. It is not preferable to arrangethe flat part 551 g at the end-winding end portion 551Je, because adifference in level may occur on the flat part 551 g when the flat part551 g is arranged at the end-winding end portion 551Je. Further, sincethe end-winding end portion 551Je is separated from the position of theclamp member 1320, when the core material 551 is formed in a flat plateshape using the clamp members 1320, the length between the position ofthe clamp member 1320 and the end-winding end portion 551Je becomeslong. Since the part between the position of the clamp member 1320 andthe end-winding end portion 551Je of the first (organic) fiber assembly1K and the second (organic) fiber assembly 1H is not clamped, the partmay be dispersed and bended from the core material 550. Thus, it ispreferable to cut the end-winding end portion 551Je so as to be close tothe folding part 551 f where the lamination can be clamped by the clampmember 1320. It is preferable to cut after (preferably, just after) thelamination is clamped by the clamp member 1320, and also preferable tocut within a range so that no difference in level may occur at the flatpart 551 g around the folding part 551 f. The above operation decreasespossibility to get dispersed and to bend, and moreover, there hardlyoccurs a difference in level at the flat part 551 g, and thus such adifference in level may not be caught, and the appearance may beimproved.

FIG. 16 shows the first embodiment and is a diagram explaining astructure of another combined original fabric roll. Here, as shown inFIG. 16, when three original fabric rolls (the main body part A 1301 a,the main body part B 1301 b, and the main body part D 1301 d) are usedfor the first original fabric roll 1305 and the second original fabricroll 1306 which are the combined original fabric roll constituted by theplurality of original fabric rolls, an ear part original fabric roll ofwhich one side is an ear part can be used for the original fabric rollsof the both sides in the width direction (the main body part A 11301 aor the main body part D 1301 d 1). At this time, the ear part of the earpart original fabric roll can be arranged so as to face the side of themain body part B 11301 b which is the main body part original fabricroll without having the ear part arranged at the center.

In FIG. 16, the first original fabric roll 1305 (the upper side roll)which is the combined original fabric roll is constituted by the mainbody part A 1301 a, the main body part B 1301 b, and the main body partD 1301 d, and they are arranged in order so as to be next to each otherfrom the main body part A 1301 a, the main body part B 1301 b, and themain body part D 1301 d in the width direction. That is, the main bodypart B 1301 b which is the main body part of the original fabric rollwithout having the ear part is arranged at the central position in thewidth direction, and the main body part A 1301 a and the main body partD 1301 d which are the ear part original fabric rolls having the earparts are arranged at the both sides of the main body part B 1301 b, andthe ear part side of the ear part original fabric roll is arranged so asto be next to the side of the main body part B 1301 b without having theear part which is arranged at the central position. Although not shownin the figure, the second original fabric roll 1306 (the lower sideroll) which is the combined original fabric roll has the same structureas the first original fabric roll 1305 (the upper side roll). That is,the main body part F 1301 f which is the main body part of the originalfabric roll without having the ear part is arranged at the centralposition in the width direction, the main body part E 1301 e and themain body part H 1301 h which are the ear part original fabric rollshaving the ear parts are arranged at the both sides of the main bodypart F 1301 f, and the ear part side of the ear part original fabricroll is arranged so as to be next to the side of the main body part F1301 f without having the ear part arranged at the central position.Although not shown in the figure, the lamination formed by the originalfabric roll of FIG. 16 can be also used as the core material 550, andthe vacuum heat insulating material 702 is manufactured using the corematerial 550.

As discussed above, the ear part of the ear part organic fiber assemblywound on the ear part original fabric roll is arranged so as not to beat both sides in the width direction of the first original fabric roll1305 or the second original fabric roll 1306, which are the combinedrolls. When the core material 550 is formed by winding up on the reel1311, both sides in the width direction are not the ear parts but thecutoff faces, and thus it becomes unnecessary to cut off the both sidesin the width direction of the core material 550, thereby obtaining thevacuum heat insulating material 702 with a low cost. At this time, whenthe main body part of the original fabric roll without having the earpart (the main body part B 1301 b) is arranged at the central positionin the width direction, and the ear part original fabric rolls havingthe ear parts (the main body part A 1301 a and the main body part D 1301d) are arranged at both sides of the original fabric roll without havingthe ear part (the main body part B 1301 b), out of the ear parts of theear part original fabric rolls (the main body part A 1301 a and the mainbody part D 1301 d), either ear part can be arranged so as to be next tothe side of the main body part of the original fabric roll (the mainbody part B 1301 b) at the central position. The ear part originalfabric roll can be arranged so that the ear part is placed at only oneside of the combined original fabric roll. At this time, compared with acase in which the ear part original fabric rolls are arranged at theboth sides of the combined original fabric roll, the cutting should bedone at only one side in the width direction, thereby obtaining thevacuum heat insulating material 702 with a low cost. As a matter ofcourse, even if it is the ear part original fabric roll having the earpart (the main body part A 1301 a or the main body part D 1301 d), theear part includes the necessary thickness of fiber and the thickness isnot so uneven, the end face position (the ridge line) is not so ragged;that is, if the level of unevenness is not too bad to cause a problem inthe heat insulating performance or the manufacturing process of the corematerial 550 or the vacuum heat insulating material 702, it is notnecessary to cut the end face in the width direction even when the earpart original fabric roll is used for the end side of the combinedoriginal fabric roll in the width direction.

Therefore, in the present embodiment, in manufacturing the core material550, there is no need to laminate the sheets one by one, and themanufacturing can be done by simple equipment which only winds up thefiber assembly IJ. It is possible to easily use the ear part fiberassembly having the ear part (for example, the fiber assembly wound onthe main body part A 1301 a or the main body part D 1301 da which is theear part original fabric roll) with the ragged ridge line (not cutoffface) in the width direction, which has been conventionally disposed offor at least one of the plurality of fiber assemblies (for example, thefirst (organic) fiber assemblies 1Ka to 1Kd and the second (organic)fiber assemblies 1Ha to 1Hd) which constitute the first (organic) fiberassembly 1K (for example, the first (organic) fiber assemblies 1Ka to1Kd) which are the combined fiber assembly IJ or the second (organic)fiber assembly 1H (for example, the second (organic) fiber assemblies1Ha to 1Hd). Accordingly, without cutting the ear part fiber assembly(the fiber assembly wound on the ear part original fabric roll) havingthe ear part, which conventionally has been disposed of the ear partoriginal fabric roll can be used as it is, thereby generating no waste.Therefore, it is possible to obtain the core material 550 and the vacuumheat insulating material 702 with a low cost.

FIG. 17 shows the first embodiment and is a perspective view showing astate where the vacuum heat insulating material 750 is folded. In FIG.17, (a) of FIG. 17 is a perspective view of the vacuum heat insulatingmaterial 750 in the folded state. (b) of FIG. 17 is an enlarged view ofthe main part of the folding part of the vacuum heat insulating material750. In the vacuum heat insulating material 750, the core material 550is inserted into the outer cover material 4 having the gas barrierproperty, and the inside is decompressed and sealed in that state. Thevacuum heat insulating material 750 is folded with two steps at thefirst slit portion 57 and the second slit portion 58 of the corematerial 550 to form folding parts 59. At this time, the folding is doneso that the width of the folding part 59 should be the width of thelapping area Xb. The width of the lapping area Xb corresponds to and issubstantially the same length as the distance (the length) between thefirst slit portion 57 and the second slit portion 58.

Further, the vacuum heat insulating material 750 is made by overlappingand laminating two sheets of the organic fiber assembly 1 and thecontinuous sheet-shaped fiber assembly 1J while being displaced by thelapping area Xb in the width direction. Because of the displacement bythe lapping area Xb, when the first slit portion 57 and the second slitportion 58 are inserted and decompressed in the outer cover material 4,the outer cover material 4 is concaved at the first slit portion 57 andthe second slit portion 58 respectively to form concave parts 751 and752. Further, a substantially trapezoidal projected part 753 is formedto be projected between the two concave parts 751 and 752 which are twoparts concaved at the first slit portion 57 and the second slit portion58. The folding part 59 includes the concave parts 751 and 752 concavedat two parts of the first slit portion 57 and the second slit portion58, and the substantially trapezoidal projected part 753 formed to beprojected between two concave parts 751 and 752. The folding can beeasily done using the concave parts 751 and 752 as a base point and byusing the slopes of the substantially trapezoidal projected part 753.Further, since the concave parts 751 and 752 at the parts of the firstslit portion 57 and the second slit portion 58 and the trapezoidalprojected part 753 formed between the concave parts 751 and 752 areformed at both sides in the thickness direction of the vacuum heatinsulating material 750, for example, even if the thickness of thevacuum heat insulating material 750 is thick, the folding can be easilydone at parts of the first slit portion 57 and the second slit portion58 formed at both faces of the sheet. Thus, the folding does not causeto break or damage the outer cover material 4 to decrease the heatinsulating performance. It is possible to obtain the vacuum heatinsulating material with a high reliability, which is able to suppressthe degradation of the heat insulating performance, and with a highdegree of freedom of arrangement, which is foldable regardless of thethickness.

For the vacuum heat insulating material 750, like the presentembodiment, having the folding part 59 constituted by the plurality ofconcave parts 751 and 752 formed by the first slit portion 57 and thesecond slit portion 58 and the substantially trapezoidal projected part753 formed at the first slit portion 57 and the second slit portion 58,the folding is confirmed in cases where the thickness t is 5 mm, 7 mm,10 mm, and 30 mm, resulting in no problems in any of the cases. However,when the thickness t of the vacuum heat insulating material 7 is thick(for example, in case of t=30 mm), as shown in FIG. 12 or FIG. 13, whenthe number of laminating sheets of the organic fiber assembly 1 and thecontinuous sheet-shaped fiber assembly 1J (the first (organic) fiberassembly 1K and the second (organic) fiber assembly 1H) is two (in FIG.12, two sheets of the first (organic) fiber assembly 1K and the second(organic) fiber assembly 1H), since there are two slit portions for onefolding part 59, the concave parts 751 and 752 are also two parts, andthe folding is not easy. Thus, it is preferable that the number oflaminating sheets should be made at least three so as to make the numberof slit portions for one folding part 59 at least three to form at leastthree concave parts by the slits. The number of laminating sheets can beappropriately selected according to the thickness t of the vacuum heatinsulating material 750, material or features of the organic fiberassembly 1, material or the tension strength of the outer cover material4, etc.

As discussed above, like the present embodiment, the core material 5 or550 is made by laminating at a plurality of times a plurality of sheets(for example, two sheets) of the organic fiber assembly 1 and thecontinuous sheet-shaped fiber assembly 1J while being displaced in thewidth direction by the predetermined length (the lapping area Xb). Thenumber of slits for one folding part becomes the number of laminatingsheets of the organic fiber assembly 1 and the continuous sheet-shapedfiber assembly 1J (a plurality of slits, for example, in case oflaminating three sheets while being displaced, three slits for onefolding part). Even if the thickness of the vacuum heat insulatingmaterial 750 is thick, it is possible to easily fold to both sides ofthe sheet face using the folding part 59 constituted by the concaveparts 751 and 752 formed by the slit portions (for example, the firstslit portion 57 and the second slit portion 58) provided at the bothsides of the sheet face.

Here, when the lapping area Xb is large, as shown in FIG. 18, a partwith a thin thickness having substantially the same length with thelapping area Xb is generated at both end portions in the width directionof the vacuum heat insulating material 750. FIG. 18 shows the firstembodiment and is a diagram of the vacuum heat insulating material 750when viewed from the width direction. The vacuum heat insulatingmaterial 750 includes a predetermined thickness part 750 c having thepredetermined thickness t and thin parts 750 a and 750 b having asubstantially half thickness of the predetermined thickness t andprovided at both sides of the predetermined thickness part 750 c in thewidth direction. In the thin parts 750 a and 750 b, since the thicknessof the heat insulation is thinner than the predetermined thickness part750 c, the heat insulating performance is slightly degraded comparedwith the predetermined thickness part 750 c. Therefore, when the lappingarea Xb is large, widths H1 and H2 (substantially the same length withthe length of the lapping area Xb) of the thin parts 750 a and 750 bbecome large, and thus the lapping area should not be too large. Thatis, when the vacuum heat insulating material 750 is folded and used, itis preferable the lapping area Xb should be at least 7 mm and no morethan around 30 mm.

Further, when the vacuum heat insulating material 750 is used withoutfolding, it is preferable the lapping area Xb should be at least 7 mm,preferably at least 10 mm, since the larger the lapping area Xb is, thelarger the frictional force becomes and also the higher the reliabilitybecomes. It is also preferable the lapping area Xb should be no morethan around 30 mm, since the larger the lapping area Xb is, the largerthe length of the thin parts 750 a and 750 b becomes and the larger apart where the heat insulating performance is slightly degraded becomes.Further, since the lapping area Xb is also influenced by the thickness tof the vacuum heat insulating material 750, it is preferable the lappingarea Xb should be around at least once and also no more than five times(preferably no more than three times) of the predetermined thickness tof the vacuum heat insulating material 750. In the present embodiment,the predetermined amount Xb is made at least 7 mm to suppress dispersingof the core material 550, and the predetermined amount Xb is made nomore than around three times of the thickness t of the core material 550which is in a substantially vacuum state in the outer cover material 4.Thus, the foldability of the vacuum heat insulating material is good,and moreover, the width of the both end portions in the width directionof the core material 550 is made small so as to suppress the degradationof the heat insulating performance. Further, if the range of the lappingarea Xb is set by the thickness of the core material 550 in thedecompressed state, the reliability can be obtained (the core material550 would not be detached or dispersed at the slit portion), andfurther, the core material 550 or the vacuum heat insulating material750 with easy foldability and good heat insulating performance can beobtained.

In the present embodiment, the example is shown in which the folding isdone by two steps at the two slit portions (the first slit portion 57and the second slit portion 58). If a plurality of, instead of usingtwo, combined original fabric rolls, each of which made by combining aplurality of original fabric rolls, are used and the winding on the reelis done by laminating the plurality of combined original fabric rollswhile being displaced by the predetermined amount Xb, there exist aplurality of slit portions, and thus the folding can be done withmultiple steps. The folding angle at one slit portion can be made small,and the core material 550 and the outer cover material 4 can be easilyfolded at the predetermined angle without being pressed by theunreasonable force. Further, since the folding can be done at onefolding part 59 with multiple steps, the folding with an acute anglealso can be done, so that the embodiment can be applied to the heatinsulating material of all kinds of equipment. Therefore, it is possibleto carry out the heat insulation of the piping of the condensation pipe,etc. of the equipment such as the refrigerator or the air-conditioner.Further, since the vacuum heat insulating material of the presentembodiment is excellent in the folding workability, when the heatinsulation is done by inserting the piping of the condensation pipe,etc. between the vacuum heat insulating material and the vacuum heatinsulating material, it is possible to curve or deform the vacuum heatinsulating material along the shape of piping, thereby suppressing theheat leakage from a gap between the vacuum heat insulating material andthe piping, and further suppressing the degradation of the heatinsulating performance.

That is, the vacuum heat insulating material 7, 702, or 750 of thepresent embodiment include: the first (organic) fiber assembly 1K madeby arranging a plurality of sheets of the sheet-shaped organic fiberassembly 1 and the continuous sheet-shaped fiber assembly 1J which arecontinuous in the length direction so as to be next to each other in thewidth direction; the second (organic) fiber assembly 1H made byarranging a plurality of sheets of the sheet-shaped organic fiberassembly 1 and the continuous sheet-shaped fiber assembly 1J which arecontinuous in the length direction so as to be next to each other in thewidth direction, and provided so as to overlap in the up-and-down,back-and-forth, or the left-and-right direction with respect to thefirst (organic) fiber assembly 1K; and the core material 5 or 550constituted by the laminated structure of the continuous sheet-shapedfiber assembly 1J formed in a flat plate shape by winding up the first(organic) fiber assembly 1K and the second (organic) fiber assembly 1Hcontinuously from the inside toward the outside while being displaced bythe predetermined amount Xb in the width direction; and the gas-barrierouter cover material 4 containing the core material 5 or 550 in aninside, and having a sealing part a periphery of which is sealed whilethe inside is decompressed, and the outer cover material 4 ishermetically sealed by sealing the sealing part while the inside of theouter cover material is substantially vacuum. It is possible to form thecore material 5 or 550 having the large width by combining the pluralityof the continuous sheet-shaped fiber assemblies 1J (the fiber assemblywound on the main part of the original fabric roll) having the smallwidth. Further, the number of the plurality of the organic fiberassemblies 1 and the continuous sheet-shaped fiber assemblies 1J and thewidth of the plurality of the organic fiber assemblies 1 and thecontinuous sheet-shaped fiber assemblies 1J are appropriately selected,thereby setting freely the width of the core material 5 or 550regardless of the width of the continuous sheet-shaped fiber assembly1J. The degree of freedom of designing the core material 5 or 550 andthe vacuum heat insulating material 7, 702, or 750 is increased.Further, in order to laminate a plurality of layers of the continuoussheet-shaped fiber assembly 1J, there is no need to purposely cut theassembly into the predetermined size and laminate the sheets one by one.Cutting equipment and laminating equipment, etc. are unnecessary, andthus the core material 5 or 550 can be easily produced with simpleequipment for only winding up the continuous sheet-shaped fiber assembly1J in a short time.

Further, the width of the organic fiber assembly 1 and the continuoussheet-shaped fiber assembly 1J (the width of the main body part of theoriginal fabric roll) can be selected appropriately so as to arrange theslit portion (the neighboring part) at the part to be folded, andfurther the lapping area (predetermined amount Xb) of the first(organic) fiber assembly 1K and the second (organic) fiber assembly 1Hcan be also appropriately selected, and thus a specific processing forfolding is unnecessary. Further, since the folding parts 59 are formedat both back and front faces with respect to the sheet face, the foldingcan be easily done in both back and front directions with respect to thesheet face using the first slit portion 57 and the second slit portion58.

Further, since the folding can be done at the connecting part betweenthe neighboring fiber assemblies 1J (the main body part A 1301 a, themain body part B 1301 b, the main body part C 1301 c, and the main bodypart D 1301 d) of the first (organic) fiber assembly 1K or the second(organic) fiber assembly 1H, there is no need to carry out a specificprocess for creating a concave part for folding, etc. The folding can beeasily done using the concave parts 751 and 752 made by the first slitportion 57 and the second slit portion 58 which are formed in theprocess of producing the core material 550. Further, the concave parts751 and 752 formed by the first slit portion 57 and the second slitportion 58 are created at both sides in the thickness direction of thevacuum heat insulating material 750 (the back and front faces of thesheet), so that, for example, even if the thickness of the core material550 is thick, since the first slit portion 57 and the second slitportion 58 are created at the both sides of the sheet face, the foldingcan be easily done compared with the case of forming at only one side.Thus at the time of folding, the core material 550 or the outer covermaterial 4 is not broken or damaged, thereby suppressing the degradationof the heat insulating performance.

Further, if the predetermined amount (the lapping area) Xb is assumed tobe at least 7 mm and no more than three times of the thickness t of thecore material 5 which is in the substantially vacuum state inside theouter cover material 4, since the lapping area Xb is at least 7 mm, thedispersing of the core material 5 can be suppressed, and moreover, thedegradation of the heat insulating performance caused by the dispersingcan be also suppressed. Further, since the lapping area Xb is no morethan three times of the thickness t of the core material 5 which is inthe substantially vacuum state inside the outer cover material 4, anexcellent foldability can be provided at the folding part 59. Therefore,it is possible to easily apply the present embodiment to the heatinsulating material of the equipment having two wall faces connectedwith the predetermined angle such as the refrigerator, etc., andmoreover, it is possible to suppress the degradation of the heatinsulating performance.

Further, if the ear part fiber assembly which has the ragged ridge line(not cutoff face) at the end side in the width direction is used for atleast one of the plurality of fiber assemblies 1J (for example, thefirst (organic) fiber assemblies 1Ka to 1Kd and the second (organic)fiber assemblies 1Ha to 1Hd) which constitute the first (organic) fiberassembly 1K or the second (organic) fiber assembly 1H, the ear partfiber assembly having the ear part (the fiber assembly wound on the earpart original fabric roll), which has been conventionally disposed of;can be used, thereby generating no waste of material. Therefore, thecore material 5 or 550, or the vacuum heat insulating materials 7, 702,or 750 can be obtained with a low cost.

Further, in the refrigerator or the equipment to which the vacuum heatinsulating material of the present embodiment is applied, the vacuumheat insulating material is folded with the predetermined angle(substantially 90 degrees, for example) at the connecting part (the slitportion) between the fiber assemblies which are located next to thefirst (organic) fiber assembly 1K or the second (organic) fiber assembly1H, and is arranged at least two continuous wall faces of the heatinsulating box having a top face, both side faces, a rear face, and abottom face. It has been conventionally difficult to fold freely thevacuum heat insulating material with the necessary predetermined angle,and is also difficult to apply the heat insulating material to twocontinuous wall faces. However, the use of the vacuum heat insulatingmaterial of the present embodiment 750 facilitates the folding at thenecessary position, and thus the vacuum heat insulating material can beapplied to two continuous wall faces connected with the predeterminedangle. Therefore, since the vacuum heat insulating material can becontinuously arranged at a corner part having the predetermined anglebetween two continuous wall faces, it is possible to largely improve thecoverage of the vacuum heat insulating material with respect to theouter surface area of a box body (an external box) except for doors ofthe equipment such as the refrigerator, etc. For example, in case of therefrigerator, the coverage can be at least 80% with respect to the outersurface area of the external box, which has been conventionallydifficult to cover with the heat insulating material:

(Manufacturing Method 4 of Core Material)

In the above discussion, explanation has been carried out for: a case inwhich the core material 5 is made by cutting the sheet-shaped fiberassembly 1 into the predetermined size and laminating a plurality ofsheets of the fiber assembly to manufacture the vacuum heat insulatingmaterial 7, or the core material 5 is made by laminating a plurality oflayers of the sheet-shaped fiber assembly 1 and cutting the end face 5 ainto the predetermined size to manufacture the vacuum heat insulatingmaterial 7 (the first manufacturing method of the core material); themethod in which the core material 5 is manufactured by continuouslywinding up the continuous sheet-shaped fiber assembly 1J (for example,the organic fiber assembly) to form a coiled shape (the secondmanufacturing method of the core material); and the method in which thecore material 5 or 550 are manufactured by combining a plurality ofcombined original fabric rolls made by combining a plurality of originalfabric rolls in the width direction to form one combined original fabricroll having a large width (for example, the combined original fabricroll 1305 or 1306) and overlapping at substantially right angles to thesheet face and winding up (the third manufacturing method of the corematerial).

In the above third manufacturing method of the core material, themanufacturing method of the core material 5 has been explained, in whichat least one first original fabric roll (the upper side original fabricroll) 1305 which is one combined original fabric roll having thepredetermined width by aligning a plurality of original fabric rolls inthe width direction, and at least one second original fabric roll (thelower side original fabric roll) 1306 which is one combined originalfabric roll having the predetermined width by aligning a plurality oforiginal fabric rolls in the width direction are used, and the fiberassembly 1K of the first original fabric roll 1305 and the fiberassembly 1H of the second original fabric roll 1306 are overlapped atsubstantially right angles to the sheet face (in the radial direction ofthe reel 1311) and wound up on the reel 1311 to manufacture the corematerial 5; here, another case will be explained, in which instead ofthe second original fabric roll 1306 which is the combined originalfabric roll, the third original fabric roll 1307 which is a singleoriginal fabric roll having the first predetermined width is used.

That is, a manufacturing method of a core material 560 will be explainedwith reference to FIG. 20 to FIG. 23. The fiber assembly 1 or 1J of thethird original fabric roll 1307 having the first predetermined width ismade by continuously winding up into a coiled shape the continuoussheet-shaped fiber assembly 1 or 1J (for example, the organic fiberassembly) composed of at least one original fabric roll having thepredetermined width. The fiber assembly 1K of the first original fabricroll 1305 which is the combined original fabric roll is made bycombining a plurality of continuous sheet-shaped fiber assemblies havingthe width smaller than the first predetermined width in the widthdirection so as to have substantially the first predetermined width. Thecore material 560 is manufactured by overlapping the fiber assembly 1 or1J of the third original fabric roll 1307 and the fiber assembly 1K ofthe first original fabric roll 1305 at substantially right angles to thesheet face and winding up, so that the first original fabric roll 1305should be located outside the third original fabric roll 1307 in theradial direction of the reel 1311.

FIG. 20 is a pattern diagram of the winding device when the windingdevice winds up on the reel 1311 at least one original fabric roll 1307having the first predetermined width and at least one combined originalfabric roll 1305 made by combining original fabric rolls having a widthless than the first predetermined width so as to have substantially thesame width as the first predetermined width. FIG. 20 shows anothermanufacturing method of core material of the present embodiment. FIG. 21is a perspective view of a core material manufactured by using andwinding up on the reel at least one original fabric roll 1307 having apredetermined width and at least one combined original fabric roll. FIG.22 is a cross sectional view of the core material manufactured by usingand winding up on the reel at least one original fabric roll having thepredetermined width and at least one combined original fabric roll. FIG.23 is a perspective view of the vacuum heat insulating material usingthe core material manufactured by using and winding up on the reel atleast one original fabric roll having the predetermined width and atleast one combined original fabric roll.

The case of manufacturing the core material 560 will be explained. Thethird original fabric roll 1307 having the first predetermined width ismade by continuously winding up into a coiled shape the sheet-shapedfiber assembly 1 or 1J (for example, the organic fiber assembly) whichis continuous in the length direction and composed of a plurality oforiginal fabric rolls including at least one original fabric roll havingthe first predetermined width. The first original fabric roll 1305 whichis at least one combined original fabric roll (for example, acombination of only original fabric rolls having the secondpredetermined width smaller than the first predetermined width, acombination of the original fabric roll having the second predeterminedwidth and an original fabric roll having the third predetermined widthsmaller than the second predetermined width, or a combination with theear part original fabric roll, etc.) is made by combining a plurality offiber assemblies which have the second predetermined width smaller thanthe first predetermined width and are continuous in the length directionso as to have substantially the same width as the first predeterminedwidth. The third original fabric roll 1307 and the first original fabricroll 1305 are overlapped at substantially right angles to the sheet faceof the fiber assemblies 1, 1J, and 1K and wound up so that the fiberassembly 1 or 1J of the third original fabric roll 1307 should belocated inside in the radial direction of the reel 1311 to manufacturethe core material 560.

In the figure, the first original fabric roll 1301 is similar to thefirst original fabric roll 1305 (or the second original fabric roll1306) explained in FIG. 12, the same signs are assigned to the sameparts and detailed explanation will be omitted. The first originalfabric roll 1301 is formed to have substantially the same width as thefirst predetermined width by combining a plurality of substantiallycylindrical (or coiled) original fabric rolls (for example, the mainbody part A 1301 a, the main body part B 1301 b, the main body part C1301 c, and the main body part D 1301 d) being wound at substantiallythe same number of times (the same number of laminating sheets) to alignwith gaps (can be aligned so as to be next to each other so that thegaps should be minute gaps, can be aligned without gaps, or can bealigned via spacers so as to have the predetermined gaps) in the widthdirection.

The third original fabric roll 1307 is similar to the substantiallycylindrical original fabric roll 1301 having the predetermined widthexplained in FIG. 6 to FIG. 9, on which the fiber assembly 1 or 1J whichhas the predetermined width and is continuous in the length direction iswound, and the same signs are assigned to the same parts and detailedexplanation will be omitted. The third original fabric roll 1307 isformed to have the first predetermined width by continuously windinginto a coiled shape the fiber assembly 1 or 1J which has the firstpredetermined width and is continuous in the length direction. Here, thefiber assembly 1 or 1J wound on the third original fabric roll 1307 ismade to be continuous in the width direction and have the same size asthe width H of the core material 560. Here, the third original fabricroll 1307 can be wound up the fiber assembly 1 or 1J having the firstpredetermined width, or can be made by after winding up the fiberassembly having the width larger than the first predetermined widthsubstantially cylindrically, cutting the width direction of the fiberassembly so that the width size should be the first predetermined width.

Here, the plurality of substantially cylindrical (or coiled) originalfabric rolls of the first original fabric roll 1305 (for example, themain body part A 1301 a, the main body part B 1301 b, the main body partC 1301 c, and the main body part D 1301 d) can have the same widths ordifferent widths. Further, the original fabric roll can be the ear partoriginal fabric roll as shown in FIG. 12.

The first original fabric roll 1305 has the same structure with thefirst original fabric roll 1301 as shown in FIG. 12. The first originalfabric roll 1305 is the combined original fabric roll in which theplurality of original fabric rolls (for example, the plurality of mainbody parts) are aligned so as to be next to each other in the widthdirection. There exists a minute gap or a predetermined gap between themain bodies located next to each other (for example, between the mainbody part of A (1301 a) and the main body part of B (1301 b)), and themain bodies located next to each other are not continuous butintermittent, and thus there exists a slit portion (for example, theslit portion A between the main body part A 1301 a and the main bodypart B 1301 b, the slit portion B between the main body part B 1301 band the main body part C 1301 c, the slit portion C between the mainbody part C 1301 c and the main body part D 1301 d, etc.). Further, inthe third original fabric roll 1307, the ear part original fabric rollhaving the ear part with a ragged ridge line generated by cutting theoriginal fabric roll material into the predetermined width can be usedfor the original fabric roll arranged at the end side in the widthdirection of the plurality of original fabric rolls (for example, themain body part A 1301 a or the main body part D 1301 d, etc.).

Therefore, at least one single original fabric roll (for example, thethird original fabric roll 1307) having substantially the same width asthe first predetermined width onto which the sheet-shaped fiber assemblyhaving the first predetermined width and continuous in the lengthdirection is wound is provided. At least one combined original fabricroll (for example, the first original fabric roll 1305) made bycombining in the width direction a plurality of sheet-shaped fiberassemblies which have the width smaller than the first predeterminedwidth and are continuous in the length direction aligned in the widthdirection so as to have substantially the same width as the firstpredetermined width is also provided. The fiber assembly 1 or 1J of thesingle original fabric roll 1307 having the first predetermined widthand the fiber assembly 1K of the combined original fabric roll 1305 areoverlapped at substantially right angles to the sheet face and wound upinto a coiled shape continuously from the inside toward the outside sothat the fiber assembly 1 or 1J of the single original fabric roll 1307should be located inside in the radial direction of the reel 1311, andthe core material 560 is formed.

Therefore, the core material 560 can be easily manufactured simply byoverlapping at substantially right angles to the sheet face and windingup the continuous fiber assemblies 1, 1J, and 1K. Further, the ear partoriginal fabric roll which has been conventionally disposed of can beused effectively, thereby obtaining the core material 560 and the vacuumheat insulating material 760 with a low cost without generating waste.

The third sheet-shaped fiber assembly (the fiber assembly 1 or 1J woundon the third original fabric roll 1307) having the first predeterminedwidth and continuous in the length direction is provided. The firstfiber assembly (the fiber assembly 1K of the first original fabric roll1305 which is the combined original fabric roll) made by aligning aplurality of sheet-shaped fiber assemblies, which have the width smallerthan the first predetermined width and are continuous in the lengthdirection, with the predetermined gaps in the width direction so as tohave substantially the same width as the first predetermined width isalso provided.

The core material constituted by the laminated structure of the fiberassembly formed in a flat plate shape by overlapping at substantiallyright angles to the sheet face of the first fiber assembly 1K or thethird fiber assembly 1 or 1J and winding into a coiled shape the firstfiber assembly and the third fiber assembly continuously from the insidetoward the outside is provided.

The gas-barrier outer cover material containing the core material in theinside, and having the sealing part the periphery of which is sealedwhile the inside is decompressed is provided.

The outer cover material is hermetically sealed by sealing the sealingpart in a state in which the inside of the outer cover material issubstantially vacuum, thereby manufacturing the vacuum heat insulatingmaterial. Since the leftover material of the ear part original fabricroll, etc. generated by cutting the original fabric roll into thepredetermined width can be effectively used, it is possible toeffectively use the leftover material of the ear part, etc. which hasbeen conventionally disposed of.

Further, between respective original fabric rolls (for example, betweenthe main body part of A and the main body part of B, between the mainbody part of B and the main body part of C, between the main body partof C and the main body part of D, etc.) of the first original fabricroll 1305 which is the combined original fabric roll, a spacer having apredetermined width, etc. is provided, so that the predetermined gap isset with the width of the spacer between respective fiber assemblies(for example, between the fiber assemblies 1Ka and 1Kb, between 1Kb and1Kc, between 1Kc and 1Kd, etc.) of the fiber assembly 1K of the firstoriginal fabric roll 1305. That is, the vacuum heat insulating material560 is also provided with a concave part having a substantiallypredetermined width, in which the piping can be embedded or at which thepositioning can be done. Thus, the working time required for the heatinsulation of the piping or the installation of the piping can bereduced, thereby obtaining the vacuum heat insulating material and theequipment with a high efficiency and a low cost.

Here, as shown in FIG. 20, when the first (organic) fiber assembly 1K(the first (organic) fiber assemblies 1Ka, 1Kb, 1Kc, and 1Kd) of thefirst original fabric roll 1305 which is the combined roll and the thirdfiber assembly 1 or 1J of the third original fabric roll 1307 areoverlapped at substantially right angles to the sheet face and wound upon the reel 1311, it is preferable to arrange the first (organic) fiberassembly 1K (the first (organic) fiber assemblies 1Ka, 1Kb, 1Kc, and1Kd) of the first original fabric roll 1305 at the outside of the fiberassembly 1 or 1J of the third original fabric roll 1307 in the radialdirection with respect to the rotating shaft 1315 of the reel 1311.

As shown in (e) of FIG. 9, the third continuous sheet-shaped fiberassembly 1 or 1J and the continuous sheet-shaped first (organic) fiberassembly 1K (the first (organic) fiber assemblies 1Ka, 1Kb, 1Kc, and1Kd) are overlapped and wound up on the reel 1311 by the predeterminedtensional force into the substantially cylindrical shape (a coiledshape), and after the substantially cylindrical fiber assemblies 1, 1J,and 1K are clamped by the clamp member 1320, the reel 1311 is removed byreleasing the tensional force. At this time, it is preferable that thewinding should be done by overlapping the fiber assemblies atsubstantially right angles to the sheet face, so that the fourth fiberassembly having the first predetermined width and without having abreak, etc. in the width direction should be arranged at the innermostcircumferential side of the substantially cylindrical fiber assemblythan the first fiber assembly having a break or a gap, etc. in the widthdirection made by combining a plurality of fiber assemblies in the widthdirection so as to be next to each other, and the third fiber assemblyshould be arranged at the inner side of the first fiber assembly in theradial direction of the reel 1311. Accordingly, when removing thesubstantially cylindrical fiber assembly from the reel 1311, the fiberassembly would not be dispersed to protrude into the innermostcircumferential side or would not be caught by the reel.

That is, in case of overlapping and winding the first fiber assembly andthe third fiber assembly, the first fiber assembly and the third fiberassembly are overlapped so that the third fiber assembly should belocated at the inner side to the first fiber assembly, and wound up onthe reel 1311 from the inside toward the outside. When the substantiallycylindrical fiber assembly wound on the reel 1311 is removed from thereel 1311, the third fiber assembly 1 or 1J which has the firstpredetermined width and is continuous in the width direction is arrangedat the innermost side of the substantially cylindrical fiber assembly.Since the fiber assembly arranged at the innermost side is continuous inthe width direction, when compared with a case in which the first fiberassembly made by combining the plurality of fiber assemblies having thewidth smaller than the first predetermined width aligned in the widthdirection is arranged at the innermost side, the fiber assembly wouldnot be dispersed, or the dispersed fiber assembly would not be caught bythe reel 1311 when the fiber assembly is removed from the reel 1311. Theremoving the fiber assembly can be easily done, which facilitatesmanufacturing the core material 560, improves the workability, andenables to reduce the manufacturing time. Further, the quality of thecore material 560, made by forming the substantially cylindrical fiberassemblies 1, 1J, and 1K removed from the reel 1311 in a flat plateshape, becomes stable.

Here, the width and the number of the plurality of original fabric rollsused for the first original fabric roll 1305 (four including the mainbody part A 1301 a, the main body part B 1301 b, the main body part C1301 c, and the main body part D 1301 d) can be appropriately set so asto be substantially the same as the first predetermined width of thefiber assembly 1 or 1J of the third original fabric roll 1307 having thefirst predetermined width. In case of aligning a plurality of rolls inthe width direction, it is preferable to set the width of the firstoriginal fabric roll 1305 (the total width by adding the plurality oforiginal fabric rolls and the gaps between the original fabric rolls) tothe width slightly smaller than the first predetermined width of thethird original fabric roll 1305, and it is preferable to overlap atsubstantially right angles to the sheet face and wind up on the reel1311 the fiber assembly 1K wound on the first original fabric roll 1305and the fiber assembly 1 or 1J wound on the third original fabric roll1307 so that the fiber assembly 1K of the first original fabric rollshould be located at the outside of the fiber assembly 1 or 1J of thethird original fabric roll. When winding up on the reel 1311, respectivefiber assemblies would not be dispersed, which facilitates the winding.

Further, the first original fabric roll 1305 and the third originalfabric roll 1307 are overlapped and wound up on the reel 1311, so thatthe fiber assembly 1K of the first original fabric roll 1305 should belocated at the outside of the fiber assembly 1 or 1J of the thirdoriginal fabric roll 1307 at substantially right angles to the sheetface. The manufacturing method of the vacuum heat insulating material560 is the same with the one of FIG. 9. In FIG. 9, when instead of oneoriginal fabric roll 1301 wound up on the reel 1311, at least twooriginal fabric rolls (for example, in case of overlapping the firstoriginal fabric roll 1305 and the second original fabric roll 1306 shownin FIG. 12 to FIG. 18, in case of overlapping the first original fabricroll 1305 and the third original fabric roll 1307 shown in FIG. 20 toFIG. 23, etc.), which are overlapped at substantially right angles tothe sheet face, are combined, the winding method, the manufacturingmethod of the core material, and the manufacturing method of the vacuumheat insulating material, etc. are the same as the processes shown inFIG. 9.

As discussed above, at least one single original fabric roll in thewidth direction (for example, the third original fabric roll 1307) ontowhich the fiber assembly that has the first predetermined width and iscontinuous in the length direction is wound is provided. At least onecombined original fabric roll (for example, the first original fabricroll 1305) formed by aligning in the width direction a plurality oforiginal fabric rolls onto which the fiber assembly having the widthsmaller than the first predetermined width and continuous in the lengthdirection is wound, and combining the plurality of original fabric rollsin the width direction so as to have substantially the same width as thefirst predetermined width is provided. The leftover material such as theear part original fabric roll, etc. can be used for the first originalfabric roll which is the combined original fabric roll, and thus itbecomes unnecessary to dispose of the leftover material, etc. which hasbeen conventionally disposed of thereby efficiently manufacturing thecore material and the vacuum heat insulating material with a low cost.

Further, the plurality of sheets of the fiber assembly 1 or 1J of thesingle original fabric roll 1307 and the fiber assembly 1K of thecombined original fabric roll 1305 are overlapped at substantially rightangles to the sheet face and wound up on the substantially cylindricalreel 1311 with the predetermined tensional force from the inside towardthe outside, and then after being clamped by the clamp member 1320, thesubstantially cylindrical fiber assembly is removed from the reel 1311by releasing the tensional force, thereby manufacturing the corematerial 560; thus the core material can be easily manufactured withsimple equipment.

FIG. 21 shows a perspective view of the core material 560 manufacturedas discussed above. In FIG. 21, the first (organic) fiber assembly 1K(for example, the first (organic) fiber assemblies 1Ka, 1Kb, 1Kc, 1Kd,and 1Ke) of the first original fabric roll 1305 (the upper side roll)and the third fiber assembly 1 or 1J (the lower side fiber assembly) ofthe third original fabric roller 1307 (the lower side roll) are wound onthe reel 1311 continuously from the inside toward the outside andlaminated, while five original fabric rolls are aligned with apredetermined gap XK in the width direction. In the core material 560,since the first fiber assembly which is the combined fiber assembly islapped over the single third fiber assembly at substantially rightangles to the sheet face of the fiber assembly 1 or 1J and wound, on theouter surface of the core material 560, the plurality of first (organic)fiber assemblies 1Ka, 1Kb, 1Kc, 1Kd, and 1Ke which constitute the firstfiber assembly which is the combined fiber assembly are arranged so asto align in the width direction with a gap (can be a minute gap or apredetermined gap).

Here, the width of the third fiber assembly can be the substantiallysame as the width of the first (organic) fiber assembly 1K. As shown inFIG. 21, the width of the third fiber assembly can be made larger thanthe width of the first (organic) fiber assembly 1K, and the first(organic) fiber assembly 1K can be arranged so as to obtain apredetermined gap corresponding to the length XT (for example, XTa orXTe) at the outside in the width direction of the first (organic) fiberassembly 1K. With this arrangement, at least one end side in the widthdirection of the third fiber assembly, there is no first (organic) fiberassembly 1K in the part of the length XT, and thus there is only thirdfiber assembly in the part of the length XT.

Therefore, when the first (organic) fiber assembly 1K and the thirdfiber assembly are overlapped and wound from the inside toward theoutside to form in a flat plate shape, the core material 560 having nofirst (organic) fiber assembly 1K in the part of the length XT at leastone end side in the width direction is manufactured. Accordingly, thecore material made by overlapping and winding up the first (organic)fiber assembly 1K and the third fiber assembly from the inside towardthe outside so as to form in a flat plate shape is inserted to the outercover material 4, the outer cover material 4 is sealed in thedecompressed state, and the vacuum heat insulating material 760 ismanufactured. Similarly to the vacuum heat insulating material 750 shownin FIG. 19, the vacuum heat insulating material 760 has thin parts H1and H2 at the end sides in the width direction. At this time, the lengthof the thin part H1 is substantially the same as XTa, the length of thethin part H2 is substantially the same as XTe, and the width H3 of thecenter part is substantially the same as the width of the first fiberassembly 1K. The thin part can be provided at both sides in the widthdirection of the vacuum heat insulating material 760; the thin part maybe provided at least one side in the width direction.

That is, the width of the third fiber assembly becomes larger than thewidth of the first (organic) fiber assembly 1K with at least the amountof the length XT (for example, in FIG. 43, a length XTa between onewidth direction end portion out of two width direction end portions ofthe third fiber assembly and the end portion at one width direction endportion side of the third fiber assembly of the first (organic) fiberassembly 1Ka which is the width direction end side fiber assembly, or alength XTe between the other width direction end portion of the thirdfiber assembly and the end portion at the other width direction end sideof the third fiber assembly of the first (organic) fiber assembly 1Kewhich is the width direction end side fiber assembly) between the first(organic) fiber assemblies 1Ka and 1Ke of the width direction end sidewhich are arranged at both end sides in the width direction out of theplurality of first (organic) fiber assemblies 1Ka, 1Kb, 1Kc, 1Kd, and1Ke aligned with the predetermined gap XK so as to be next to each otherin the width direction in the first (organic) fiber assembly 1K and theend portion in the width direction of the third fiber assembly. In thesame manner as the vacuum heat insulating material 750, the thin part H1(or H2) can be obtained at least one end side in the width direction ofthe vacuum heat insulating material 760.

That is, in the vacuum heat insulating material 750 or 760, the corematerial 550 or 560 has the predetermined thickness t when the corematerial 550 or 560 is decompressed and sealed in the outer covermaterial 4, and the cross sectional shape of the width direction endportion of the core material 550 or 560 is a thin stepped shape (thethin part H1 or H2) projected toward the outside in the width direction.

As has been discussed, since the vacuum heat insulating material 750 or760 are provided, without performing a specific processing, etc., at oneend side or both sides of the core material 550 or 560 in the widthdirection, with the thin part (in FIG. 19, H1 and H2) having thethickness thinner than the thickness of the vacuum heat insulatingmaterial 750 or 760 (the thickness t of the core material 5, 550, or560). When, in case of folding one vacuum heat insulating material 750or 760 cylindrically, etc., the end faces (the thin part (H1 or H2)) inthe width direction are overlapped in the thickness direction and usedcontinuously, or when end faces (the thin parts) in the width directionof the plurality of at least two, vacuum heat insulating materials 750or 760 are overlapped in the thickness direction and used continuously,if the end faces in the width direction of the plurality of vacuum heatinsulating materials 750 or 760 are overlapped so that surfaces in thethickness direction of the thin parts should be contacted with eachother, the plurality of vacuum heat insulating materials 750 or 760 canbe made to contact each other at the part where the core material 550 or560 exists. Moreover, since the thin parts having the thin thickness(around a half of the thickness if one sheet is displaced in thetwo-sheet lamination) are overlapped, the jointing thickness of thecontacting part can be made small, and further, the heat leakage fromthe contacting part can be reduced, thereby obtaining the vacuum heatinsulating material 750 or 760 with high performance and the equipmentwhich mounts the vacuum heat insulating material 750 or 760 such as thecompressor, the refrigerator, the water heater, etc.

Further, a cross sectional shape of a cross section at substantiallyright angles to the width direction of the end faces in the lengthdirection of the plurality of vacuum heat insulating materials 7, 700,701, 750, or 760 is a substantially triangular shape of which athickness becomes smaller toward the outside in the length direction. Ifslope face parts of the substantially triangular shape (a slope facepart having the length L2 in FIG. 11) are connected so as to contactwith each other, it is possible to make the plurality of vacuum heatinsulating materials contact at the part where the core material 550 or560 exists. Further, the jointing thickness of the contacting part canbe made small, and moreover, the heat leakage from the contacting partcan be reduced, thereby obtaining the vacuum heat insulating materials7, 700, 701, 750, or 760 with a high performance and the equipment whichmounts the vacuum heat insulating material 7, 700, 701, 750, or 760 suchas the refrigerator, etc.

Here, as for the shape of the end portion in the length direction, theorganic fiber assembly 1 or the continuous sheet-shaped fiber assembly1J is not necessarily continuous in the length direction, but it issufficient that the organic fiber assembly 1 or the continuoussheet-shaped fiber assembly 1J should have a substantially triangularcross sectional shape when the fiber assembly is laminated. That is, inthe vacuum heat insulating material 7, 700, 701, 750, or 760 having thepredetermined length L, the predetermined width H, and the predeterminedthickness t, in which the core material 5, 550, or 560 are decompressedand hermetically sealed inside the outer cover material 4, it issufficient that the core material 5, 550, or 560 should be constitutedby a laminated structure of the organic fiber assembly 1 or thecontinuous sheet-shaped fiber assembly 1J, and the cross section of atleast one end portion in the length direction or in the width directionshould be a substantially triangular shape of which the thicknessbecomes smaller toward the outside. Further, when the core material 5,550, or 560 is a laminated structure being wound up the sheet-shapedorganic fiber assembly 1 or the continuous sheet-shaped fiber assembly1J which has the predetermined width H and is continuous in the lengthdirection continuously from the inside toward the outside, and the corematerial 5, 550, or 560 is hermetically sealed in the outer covermaterial 4, if the end portion in the length direction of the corematerial 5, 550, or 560 has a substantially triangular shape, the sameeffect can be obtained.

Further, also in the thin part shape in the width direction (a shape ofthin projection), the organic fiber assembly 1 or the continuoussheet-shaped fiber assembly 1J is not necessarily continuous in thelength direction, or a plurality of layers of fiber assembly having thelength L can be laminated. That is, in the vacuum heat insulatingmaterial 7, 700, 701, 750, or 760 having the predetermined length L, thepredetermined width H, and the predetermined thickness t, in which thecore material 5, 550, or 560 is decompressed and hermetically sealed inthe outer cover material 4, at either of the end portions in the lengthdirection and in the width direction, it is sufficient that the thinparts 750 a and 750 b having thin thickness should be provided, and thethin parts 750 a and 750 b should be projected toward the outside.Further, if the core material 5, 550, or 560 is a laminated structuremade by overlapping and laminating the plurality of sheet-shaped organicfiber assemblies 1 or the continuous sheet-shaped fiber assembly 1Jhaving the predetermined width H, and the thin part 750 a is made bylaminating the plurality of layers of the plurality of organic fiberassembly 1 or the continuous sheet-shaped fiber assembly 1J while atleast one of the plurality of organic fiber assemblies 1 and thecontinuous sheet-shaped fiber assembly 1J is displaced by apredetermined amount in the width direction, the same effect can beobtained.

As discussed, the vacuum heat insulating material 750 or 760 of thepresent embodiment is the flat plate shape having the predeterminedthickness, the cross sectional shape of the end portion in one direction(for example, in the length direction) of the flat plate shape is asubstantially triangular shape, of which the thickness becomes smallertoward the outside, or the cross sectional shape of the end portion inanother direction (for example, in the width direction) is a steppedshape having the thin part of which the thickness is thin. The vacuumheat insulating material 750 or 760 can be easily manufactured by asimple method of overlapping and winding up the core material 550 or560, and the leftover material can be effectively used.

Further, since the shape of end portion can be made a connectable shapewithout performing a specific processing, etc. in the length directionor the width direction, if the end portions are contacted and connected,the jointing thickness of the contacting part can be reduced, andmoreover, the heat leakage from the contacting part can be reduced,thereby obtaining the vacuum heat insulating material 750 or 760 with ahigh performance or the equipment which mounts the vacuum heatinsulating material 750 or 760 such as the compressor, the refrigerator,the water heater, etc.

Here, in the same manner as the core material 5 or the core material 550shown in FIG. 9, since the two clamp members 1320 are moved in theopposite directions (alienating directions) while the core material 560is clamped at two positions by the two clamp members 1320, the fiberassembly is bended (folded) by a folding end portion 560 f at theclamped part, and the core material 560 is formed in a flat plate shape.The core material 560 folded at the folding end portion 560 f which isthe end portion in the length direction of the core material 560 is,similarly to the core material 5 shown in FIG. 9, inserted into theopening part 4 a of the outer cover material 4 from an upstream side 560fa in the winding direction of the fiber assemblies 1, 1J, and 1K, andthe sealing is done while the inside is decompressed, thereby completingthe vacuum heat insulating material 760.

FIG. 22 shows a cross sectional shape in the width direction of the corematerial 560 which is folded into a flat plate shape. The core material560 is made by overlapping at substantially right angles to the sheetface and winding up continuously from the inside toward the outside thefiber assembly 1 or 1J, which is single and continuous in the widthdirection and also continuous in the length direction, and the first(organic) fiber assemblies 1K, which are plural in the width direction,that is, divided into a plurality in the width direction and continuousin the length direction, and is folded into a flat plate shape. Then,the fiber assembly 1 or 1J which is single and continuous in the widthdirection and the first (organic) fiber assembly 1K made by aligning theplurality of fiber assemblies in the width direction are overlapped sothat the fiber assembly 1 or 1J should be located at the inner side ofthe first (organic) fiber assembly 1K and wound into a coiled shape fromthe inside. Thus, the winding is done so as to arrange the first(organic) fiber assembly 1K (the first (organic) fiber assemblies 1Ka,1Kb, 1Kc, 1Kd, and 1Ke) at the outer surface of the core material 560.At this time, a gap between the respective first (organic) fiberassemblies 1Ka, 1Kb, 1Kc, 1Kd, and 1Ke of the first (organic) fiberassembly 1K is set to a predetermined gap XK, and a slit portion 560K(the third slit portion) is formed. The predetermined gaps XK arerespectively predetermined gaps XKab, XKbc, XKcd, and XKde, and therespective predetermined gaps XKab, XKbc, XKcd, and XKde can be the sameor different.

FIG. 23 shows the hermetically sealed vacuum heat insulating material760, in which the core material 560 is inserted into the inside of theouter cover material 4, the inside is decompressed, and the opening part4 a of the outer cover material 4 is sealed in that state. The vacuumheat insulating material 760 is provided with, in the width direction, aplurality of concave parts 760 x being continuous in the lengthdirection and having substantially the same width as the predeterminedgap XK provided at the core material 560 (which is a groove part, forexample, the first concave part 760 x 1, the second concave part 760 x2, the third concave part 760 x 3, and the fourth concave part 760 x 4)in the width direction. Here, the widths of the first concave part 760 x1, the second concave part 760 x 2, the third concave part 760 x 3, andthe fourth concave part 760 x 4 can be the same or different, which canbe appropriately set according to the size of the piping, etc.

Here, the predetermined gap XK is continuous in the winding direction(the length direction) of the core material 560. When the vacuum heatinsulating material 760 is manufactured using the core material 560, aconcave part 560X (a groove part) which has substantially the same widthas the predetermined gap XK, is continuous in the length direction, andhas the depth being around ¼ of the thickness of the vacuum heatinsulating material 760 is formed at both sides of the flat face of theflat-plate-shaped vacuum heat insulating material 760 (the depth becomesaround a half (around ½) of the thickness of the vacuum heat insulatingmaterial 760 when the depths of the concave at the both sides areadded). At least a part of the piping (for example, a condensation pipe,a suction pipe, a discharge pipe, etc.) or the lead wire, etc. isarranged in the concave part, thereby easily carrying out the heatinsulation of the piping and the storage of the lead wire without usinga separate member. Further, as for the positioning of the piping and thelead wire, etc., the positioning can be done simultaneously only byarranging the piping and the lead wire, etc. in the concave part 760 x.A separate member for the positioning is unnecessary, and theworkability can be also largely improved. Further, it is unnecessary toseparately provide a concave part for folding using laser processing,etc., and the folding can be easily done with the concave part 760 x.

As explained above, the vacuum heat insulating material manufacturingapparatus according to the present invention includes: the reel 1311 forwinding up the organic fiber assembly 1 having the predetermined widthwound on the substantially cylindrical original fabric roll 1301 whichis cut into the predetermined width and the continuous sheet-shapedfiber assembly 1J at a predetermined number of times R; cutting meansfor cutting the organic fiber assembly 1 and the continuous sheet-shapedfiber assembly 1J wound up on the reel 1311; a forming member (forexample, the clamp member 1320) for removing from the reel 1311 theorganic fiber assembly 1 and the continuous sheet-shaped fiber assembly1J wound up on the reel 1311 at the predetermined number of times R andcut, and then forming the organic fiber assembly 1 and the continuoussheet-shaped fiber assembly 1J into the flat core material 5, 550, or560. It is possible to easily manufacture the core material 5, 550, or560 by a simple structure, and also to reduce the manufacturing time.Further, since the winding is done continuously in the windingdirection, there is no need to cut the end face in the length direction,and further it is unnecessary to cut the core material 5, 550, or 560,since the original fabric roll is used, in which the width direction hasbeen previously cut. Further, the manufacturing facility to cut the endface of the core material 5, 550, or 560 is unnecessary, and also thetime to cut is unnecessary, and thus the manufacturing facility can beprovided with a low cost, thereby obtaining the core material 5, 550, or560, and the vacuum heat insulating material 7, 702, 750, or 760 with alow cost. Further, the plurality of main body parts of (fiber assembly)of the original fabric roll having the small width are combined, therebymanufacturing the core material 550 or 560 having the large width.Further, the widths of the number of the plurality of original fabricrolls or the plurality of original fabric rolls are appropriatelyselected, so that the width of the core material 550 or 560 can befreely set regardless of the width of the original fabric roll, and thusa degree of freedom of designing the core material 5, 550, or 560increases. Further, since the core material 550 or 560 having the largewidth can be manufactured from the original fabric rolls having thesmall width, the storage space of the original fabric roll can be small;there is no need to have a large storage space. Further, it is notnecessary to purposely cut the respective sheets for laminating theplurality of fiber assemblies into the predetermined size, or tolaminate the sheets one by one. Further, compared with a case in whichthe core material is formed by folding continuous belt-like sheet-shapedmember alternatively in different directions and laminating with foldinglines, an expensive apparatus, etc. for folding with folding lines isunnecessary. Therefore, as for the manufacturing the core material 5,550, or 560, the laminating equipment, etc. is unnecessary, and thus itis possible to easily manufacture the core material 5, 550, or 560 in ashort time with simple equipment for only winding up the continuoussheet-shaped fiber assembly 1J.

Further, in the manufacturing apparatus of the vacuum heat insulatingmaterial 7, 702, 750, or 760 of the present invention, the reel 1311includes the plurality of divided circumferential members 1312, and atleast one (for example, movable circumferential members 1312 a and 1312b) of the plurality of circumferential members 1312 is made movable inthe direction of the center of rotation (the rotating shaft 1315). Afterwinding up the organic fiber assembly 1 and the continuous sheet-shapedfiber assembly 1J on the reel 1311, the movable circumferential members1312 a and 1312 b are moved in the direction of the center of rotation,and the tensional force of the organic fiber assembly 1 and thecontinuous sheet-shaped fiber assembly 1J is released. Then, the organicfiber assembly 1 and the continuous sheet-shaped fiber assembly 1J areremoved from the reel 1311. It is possible to easily remove thecontinuous sheet-shaped fiber assembly 1J wound substantiallycylindrically from the reel 1311 after releasing the tensional force ofthe continuous sheet-shaped fiber assembly 1J which is wound on the reel1311, for example, substantially cylindrically with the predeterminedtensional force. That is, the tensional force of the continuoussheet-shaped fiber assembly 1J which is wound on the reel 1311 with thepredetermined tensional force is released, and thereby the continuoussheet-shaped fiber assembly 1J which is wound on the reel 1311 can beeasily removed from the reel 1311.

Further, in the manufacturing apparatus of the vacuum heat insulatingmaterial 7, 702, 750, or 760 of the present invention, when the organicfiber assembly 1 and the continuous sheet-shaped fiber assembly 1J areremoved from the reel 1311, the fiber assembly is removed after clampedby the clamp member 1320. Thus, the organic fiber assembly 1 and thecontinuous sheet-shaped fiber assembly 1J can be removed from the reel1311 with a simple structure. Further, while the continuous sheet-shapedfiber assembly 1J is clamped at two positions using the two clampmembers 1320 (the clamp members 1320 c and 1320 d), the two clampmembers 1320 c and 1320 d are made movable or moved in the oppositesides of the substantially straight line direction (with substantially180 degrees in the opposite directions). At this time, the continuoussheet-shaped fiber assembly 1J being wound up at a plurality of timesand laminating a plurality of layers is pulled in the oppositedirections by the two clamp members 1320 c and 1320 d and formed in aflat plate shape with being folded at the clamped parts. Accordingly,the flat core material 5, 550, or 560 can be easily formed with simpleequipment by continuously winding up the continuous sheet-shaped fiberassembly 1J from the inside toward the outside for laminating aplurality of layers.

Further, the manufacturing method of the vacuum heat insulating material7, 702, 750, or 760 of the present invention includes: a winding stepfor winding up on the reel 1311 the continuous sheet-shaped fiberassembly 1J having the predetermined width wound on the substantiallycylindrical original fabric roll 1301 cut into the predetermined widthat a predetermined number of times R; a cutting step for cutting thecontinuous sheet-shaped fiber assembly 1J wound up on the reel 1311; aremoving step for removing the continuous sheet-shaped fiber assembly1J, which is wound up on the reel 1311 at the predetermined number oftimes R and cut, from the reel 1311; a forming step for forming thecontinuous sheet-shaped fiber assembly 1J removed from the reel 1311 atthe removing step into the flat core material 5, 550, or 560; and anouter cover material sealing step for containing the core material 5,550, or 560 in an inside of the outer cover material 4 havinggas-barrier property, decompressing the inside, and sealing in thatstate, thereby manufacturing the core material 5, 550, or 560 with asimple method in a short time. Further, since the winding is carried outcontinuously in the winding direction, it becomes unnecessary to cut theend face in the length direction, and since the original fabric roll ofwhich the width direction has been previously cut is used, it alsobecomes unnecessary to cut the width direction, and thus there is noneed to cut the core material 5, 550, or 560. Therefore, themanufacturing facility to cut the end face of the core material 5, 550,or 560 is also unnecessary, and the time to cut is unnecessary, and thusthe core material 5, 550, or 560 and the vacuum heat insulating material7, 702, 750, or 760 can be obtained with a low cost.

Further, according to the manufacturing method of the vacuum heatinsulating material 7, 702, 750, or 760 of the present invention, theremoving step includes: a clamping step for clamping by the clamp memberthe continuous sheet-shaped fiber assembly 1J which is wound up on thereel 1311 at the predetermined number of times R and cut; a fiberassembly tensional force releasing step for releasing the tensionalforce, with respect to the reel 1311, of the continuous sheet-shapedfiber assembly 1J clamped by the clamping step; and a reel removing stepfor removing from the reel 1311 the continuous sheet-shaped fiberassembly 1J of which the tensional force is released at the tensionalforce releasing step, thereby removing the continuous sheet-shaped fiberassembly 1J from the reel 1311 with a simple method.

Further, according to the manufacturing method of the vacuum heatinsulating material 7, 702, 750, or 760 of the present invention, at theforming step, the continuous sheet-shaped fiber assembly 1J is clampedat two positions using two clamp members 1320 (the clamp members 1320 cand 1320 d), and the core material is formed in a flat plate shape bymoving the two clamp members (the clamp members 1320 c and 1320 d) inthe substantially opposite directions, thereby manufacturing thesheet-shaped core material 550 with a simple method only using the clampmember 1320.

Further, since the continuous sheet-shaped fiber assembly 1J is formedby the continuous organic fiber into a sheet-shape, compared with thecase where the glass fiber which is inorganic fiber is used, harmfuleffect to the human body due to the powder dust can be suppressed, andthe core material 550, and the vacuum heat insulating material 7, 702,750, or 760 can be obtained with a good recyclability.

In the present embodiment, the manufacturing apparatus and themanufacturing method can use a continuous organic fiber 2 for the fiberand can manufacture the core material 5, 550, or 560 or the vacuum heatinsulating material 7, 702, 750, or 760, etc. by using the organic fiberassembly 1 and the continuous sheet-shaped fiber assembly 1J, winding upon the reel continuously from the inside toward the outside. In themanufacturing apparatus of and the manufacturing method of the presentembodiment, the fiber to be used is not always a continuous long fiber.However, it is sufficient that the fiber assembly is continuoussheet-shaped, and that the continuous sheet-shaped fiber assembly 1J maynot be broken, etc. when wound up on the reel 1311 with thepredetermined tensional force. Therefore, the fiber assembly is notnecessarily the organic fiber assembly 1, or the continuous sheet-shapedfiber assembly 1J, but can be inorganic fiber assembly. In themanufacturing apparatus and the manufacturing method of the presentembodiment, the same effect can be achieved if it is the continuoussheet-shaped fiber assembly. Here, the continuous sheet-shaped fiberassembly can be used as it is; it is more preferable that the continuoussheet-shaped fiber assembly is in the state of the original fabric rollwound on the original fabric roller, since the manufacturing is easy,and moreover, the usability can be further improved.

Here, when the organic fiber assembly 1 and the continuous sheet-shapedfiber assembly 1J are overlapped and wound up to manufacture the corematerial 550, it is also possible to manufacture the core material bywinding up without being overlapped with the predetermined amount Xb. Ifthe number of sheets of the organic fiber assembly 1 and the continuoussheet-shaped fiber assembly 1J to be overlapped is increased, it ispossible to change the number of kinds of the fiber assembliescorrespondingly to the number of sheets to be overlapped. That is, sinceit is possible to use fiber assembly of which the fabric weight isdifferent or mix fiber assemblies in which fibers having different kindsto be used for the fiber assembly (for example, fibers having differenttemperature characteristics, fibers having different fiber diameters,fibers having good tension strength, fibers having different heatconductivities, etc.) according to the environment of usage of theequipment, the core material and the vacuum heat insulating materialsuitable to the type of usage can be obtained. Therefore, it is possibleto acquire both the heat insulating performance and high temperatureproof strength, both to acquire the heat insulating performance and toavoid harmful effect to human body, and to improve the recyclability. Atthis time, even if a plurality of sheets of the fiber assembly are used,it is not necessary to overlap the respective sheets while beingdisplaced by the predetermined amount Xb, and the core material 5 can beformed by winding up the fiber assemblies having the same width withoutbeing displaced. Further, the core material 5 can be also formed bywinding up the fiber assemblies having different widths.

Here, when the vacuum heat insulating material used for the heatinsulation for the hot-water tank storing hot water of the water heateror the hot temperature parts (for example, at least 70 degrees Celsius)of the equipment having parts of high temperature such as a compressor,etc. is required, fibers having the high temperature proof strength (theheat-resistant property) should be used for at least one sheet of fiber(fibers using one of or combining LCP or PPS which is the organic fiber,or the glass fiber which is the inorganic fiber, etc.). At this time,fiber assembly using the fiber having the high temperature proofstrength (the heat-resistant property) is arranged so as to be locatedat the surface side when the core material is formed to manufacture thevacuum heat insulating material. In the above discussed manner, as thevacuum heat insulating material, the fiber assembly using the fiberhaving the high temperature proof strength (the heat-resistant property)is arranged at the surface side, so that the heat insulation of theequipment having the high temperature part is made possible by arrangingthe vacuum heat insulating material of which the fiber assembly usingthe fiber having the high temperature proof strength (the heat-resistantproperty) should be located at the high temperature part side of theequipment.

Further, in case of the vacuum heat insulating material used for theheat insulation of the equipment such as the refrigerator, etc. which isnecessary to have the high heat insulating performance and the heatinsulating box, etc., since the heat insulating performance is required,the fiber of which the solid heat conductivity is small and theimprovement of the heat insulating performance can be expected (forexample, polystyrene which is organic fiber, or the glass fiber which isthe inorganic fiber, etc.) should be used for at least one sheet offiber.

Further, in case of the vacuum heat insulating material used for theheat insulation of the equipment which requires the recyclability suchas the refrigerator, the air-conditioner, or the water heater, etc., ifthe glass fiber which is the inorganic fiber is used, for example, incase of the refrigerator, since the refrigerator is demolished for eachproduct in a recycle factory, and the glass fiber is mixed with urethanewaste, etc. and supplied to thermal recycle; however, the recyclabilityof the glass fiber is not good such that it causes to degrade thecombustion efficiency, to remain as residue, etc., and thus it ispreferable to use organic fiber such as polyester, polystyrene, or LCP,etc.

Further, when considering environment problem or harmful effect to thehuman body, since the glass fiber is stiff and brittle, at the time ofmanufacturing or destructing the vacuum heat insulating material, powderdust may scatter to cause to stick to skin/mucous membrane of a worker,which may cause stimulus, and a problem exists in the usability andworkability; and thus it is preferable to use organic fiber.

(Refrigerator)

FIG. 19 shows the first embodiment and is a cross sectional view of therefrigerator 100. In FIG. 19, a food storage room of the refrigerator100 includes a refrigerating room 150 arranged at the topmost part andprovided with a refrigerating room door 160 which is the opening/closingdoor, a switching room 200 which is able to switch the temperature bandfrom the one for frozen storage (−18 degrees Celsius), for cool storage,for vegetables, for chilled storage, for softly freezing (−7 degreesCelsius), etc. arranged at lower to the refrigerating room 150 andprovided with a switching room door 210 which is a drawer type door; anice making room 500 arranged in parallel to the switching room 200 andprovided with an ice making room door 510 which is a drawer type door; afreezing room 300 arranged at the lowermost part and provided with afreezing room door 310 which is a drawer type door; and a vegetable room400 arranged between the freezing room 300 and the switching room 200and the ice making room 500 and provided with a vegetable room door 410which is a drawer type door, and so on. On the surface of the front faceside of the refrigerating room door 160 of the refrigerator 100 isprovided with an operation panel 180 constituted by an operation switchfor adjusting temperature or setting of each room and a liquid crystalfor displaying a temperature of each room at that time, and so on.

At a lower part of the rear face side of the refrigerator 100, a machineroom 601 provided with a compressor 600 which forms a refrigeratingcycle, and a cooler room 640, in which a cooler 650 and a fan 660 forblowing air cooled by the cooler 650 to the refrigerating room 150 orthe switching room 200, and so on are arranged.

From the cooler room 640, a cooling air passage 680 for introducing thecooling air cooled by the cooler 650 to the refrigerating room 150 andan air passage 690 for introducing the cooling air cooled by the cooler650 to the freezing room 300, and so on are provided.

Further, at the top part of the refrigerator 100, on the rear face ofthe heat insulating wall arranged at the rear face of the refrigeratingroom 150, a control board 900 (not shown) is contained in a controlboard containing room 910 (not shown). The control board 900 is providedwith control lead wires and power source wires connected to thecompressor 600 and a damper, etc. which opens/closes the cooling airpassages for controlling temperatures of the storage rooms such as therefrigerating room 150 or the freezing room 300, etc. by opening/closingcontrol of the compressor 600 and the cooling air passages.

Here, the switching room 200 is provided with a containing case 201, thefreezing room 300 with a containing case 301, and the vegetable room 400with a containing case 401, respectively, and it is possible to storefood in these cases.

Here, a vacuum heat insulating material 750 or 760 is provided at theheat insulating wall between the machine room 601 located at the lowerpart of the refrigerator 100 and the cooler room 640. The vacuum heatinsulating material 750 or 760 can be provided as a single unit or italso can be embedded or arranged in the foam insulation 11.

Namely, the refrigerator 100 of the present embodiment includes aplurality of storage rooms including the refrigerating room 150 providedwith the opening/closing refrigerating room door 160, the switching room200, the freezing room 300, the vegetable room 400, and the ice makingroom 500, respectively provided with the switching room door 210, thefreezing room door 310, the vegetable room door 410, and the ice makingroom door 510 which are drawer type doors, and so on; the cooler 650arranged at the rear face side of the storage rooms through thepartition wall for generating cooling air to be blown to the storagerooms; the internal fan 660 for blowing the cooling air generated by thecooler 650 to each storage room; the cooler room 640 arranged at therear face side of the storage rooms through the partition wall forcontaining the cooler and the internal fan; the machine room 601arranged at the lower part or the upper part of the refrigerator forcontaining the compressor 600 which forms the refrigerating cycle; thefirst heat insulating wall arranged between the machine room 601 and thecooler room 640; the second heat insulating wall arranged between themachine room and storage rooms; and the vacuum heat insulating material7, 702, 750, or 760 which is provided at either of the doors of thestorage rooms, the first heat insulating wall, or the second heatinsulating wall, and constituted by laminated structure of the organicfiber assembly 1 made by the sheet-shaped organic fiber 2, and formed byinserting the core material 5 or 550 having a cutting part, of which theend face has been cut, into the outer cover material 4, and sealing thesealing part of the outer cover material 4 around a periphery of thesheet so as to hermetically seal the inside in a substantially vacuumstate.

The vacuum heat insulating material 750 provided at the heat insulatingwall between the machine room 601 and the cooler room 640 has a W-shapedcomplex structure, in which the vacuum heat insulating material isfolded at three positions by the folding part 59 formed by the firstslit portion 57, the second slit portion 58, etc. as shown in FIG. 17.In the vacuum heat insulating material 750, the core material 5 or 500made by laminating the organic fiber assembly 1 made of long fibers isinserted to the outer cover material 4 in the state of the sheet havingthe predetermined size, and the end face of which is cut (cutoff). Afterdrying and vacuuming, the vacuum heat insulating material 750 iscompleted by sealing the inserted part of the outer cover material 4with heat deposition, etc.

Further, the vacuum heat insulating material 750 is, as shown in FIG.17, folded by the folding part 59 formed by the first slit portion 57,the second slit portion 58, etc. into an L shape and arranged so as tobridge the top face wall and the rear face wall of the refrigerator 100,and further, as has been discussed, folded into a W shape and arrangedso as to bridge the rear face wall and the bottom face wall of therefrigerator 100. Further, as shown in FIG. 23, since the vacuum heatinsulating material 760 is provided with the concave part 760X which isa groove part continuous in the length direction, and thus the vacuumheat insulating material 760 can be folded by the concave part 760X intothe L shape or the W shape, similarly to the core material 750. Asdiscussed above, if the vacuum heat insulating material 750 or 760explained in the present embodiment is used by folding, etc., the vacuumheat insulating material 750 or 760 can be easily applied to the wallface having a complicated shape such as the machine room 601 containingthe compressor 600 of the refrigerator.

Here, in the present embodiment, when a plurality of sheets (forexample, two sheets) of the organic fiber assembly 1 and the continuoussheet-shaped fiber assembly 1J are overlapped while being displaced bythe predetermined length (the lapping area Xb) in the width directionand laminated at a plurality of times to manufacture the core material 5or 550, the number of slits for one folding part becomes the number ofoverlapped sheets (a plurality, in case of overlapping three sheets withdisplacement, three slits for one folding part) of the organic fiberassembly 1 and the continuous sheet-shaped fiber assembly 1J, so thateven if the thickness of the vacuum heat insulating material 750 isthick, it is possible to easily fold to both sides of the sheet face atthe folding part 59 (the first slit portion 57, the second slit portion58). Further, trapezoidal parts are formed, of which parts of the firstslit portion 57 and the second slit portion 58 are concaved, andmoreover, are provided at both sides of the vacuum heat insulatingmaterial 750 in the thickness direction, for example, even if thethickness is thick, the vacuum heat insulating material 750 can beeasily folded at the folding parts of the first slit portion 57 and thesecond slit portion 58 formed at both sides of the sheet, and thus theouter cover material 4 is not broken or damaged.

Therefore, the vacuum heat insulating material 750 of the presentembodiment is folded at the connecting part (the slit portion) betweenthe fiber assemblies which are located next to each other of the first(organic) fiber assembly 1K or the second (organic) fiber assembly 1Hwith a predetermined angle (around 90 degrees, for example), and thevacuum heat insulating material can be arranged at, for example, atleast two continuous wall faces of the heat insulating box having thetop face, the both side faces, the rear face, and the bottom face of therefrigerator 100. Specifically, in case of the refrigerator 100, whenthe vacuum heat insulating material is folded into an L shape byassuming the predetermined angle is around 90 degrees, the vacuum heatinsulating material can be applied to two continuous wall faces such as(1) the side wall and the rear face wall, (2) the top face wall and therear face wall, (3) the top face wall and the side wall, (4) the bottomface wall and the side wall, (5) the bottom face wall and the rear facewall, etc. Further, when the vacuum heat insulating material is foldedinto a U shape by folding at two positions, the vacuum heat insulatingmaterial can be applied to three continuous wall faces such as (1) therear face wall and both side walls, (2) the top face wall and both sidewalls, (3) the bottom face wall and both side walls, (4) the top facewall, the rear face wall, and the bottom face wall, etc.

As explained above, the vacuum heat insulating material 760 can be usedinstead of the vacuum heat insulating material 750. If the vacuum heatinsulating material 760 is used, similarly to the folding part 59 (thefirst slit portion 57 or the second slit portion 58) of the vacuum heatinsulating material 750, the vacuum heat insulating material 760 can beeasily folded at the concave part 760X, further, similarly to the firstslit portion 57 or the second slit portion 58 of the vacuum heatinsulating material 750, the piping (the condensation pipe or thesuction pipe), etc. is arranged and contained in the concave part 760X,and thus the heat insulation of the piping can be easily carried out.Moreover, fixing or positioning of the piping on the outer surface ofthe vacuum heat insulating material, which has been conventionallydifficult, can be easily carried out only by containing the piping inthe concave part 760X without providing separately the containing partof the piping by the laser processing, etc. Further, the positioning isenabled without providing a separate fixing member. It can be easilydone without any member, etc. Further, when the wiring (a controllinglead wire, etc.) is contained in the concave part 760X, the wiring canbe stored without providing a separate containing part of the wiring,and further, the positioning is enabled without providing a separatefixing member. At this time, the width of the concave part 760X can beset according to the size of the piping or the wiring to be contained.That is, since the width of the concave part 760X is substantially thesame as the predetermined gap XK (for example, the predetermined gapsXKab, XKbc, XKcd, and XKde) between the respective first (organic) fiberassemblies 1Ka, 1Kb, 1Kc, 1Kd, and 1Ke of the first (organic) fiberassembly 1K, the predetermined gap XK can be set appropriately.

Further, it is needless to say, the vacuum heat insulating material 750or 760 of the present embodiment can be easily applied to, other thanthe refrigerator 100, the heat insulation around the cylindricalcontainer such as the compressor or the hot-water tank or the heatinsulation of the housing (container) of the outdoor unit of theair-conditioner or the heat source equipment of the water heater.

In the present embodiment, the application examples to the refrigerator100 have been explained, and the application is possible to theequipment such as the cooling/air-conditioning apparatus other than therefrigerator 100. Further, in the present embodiment, the vacuum heatinsulating material 750 with a complicated structure such as “L” shapewith one folded position or “W” shape with three folded positions havebeen explained; however, the vacuum heat insulating material 750 can bealso easily applied to “Z” shape with two folded positions, and further“U” shape with two folded positions or “C” shape or “J” shape with aplurality of curving positions. Therefore, the vacuum heat insulatingmaterial of the present embodiment can be applied to the part with acomplicated shape (a part of “Z” shaped, “U” shaped, “C” shaped, “J”shaped, or “W” shaped, etc., or a part with a projection or a piping,etc.) to which it has been difficult to mount the vacuum heat insulatingmaterial since the bending work is difficult, and thus it is possible tomount the vacuum heat insulating material to all the equipment. Theequipment such as the refrigerator, etc. which mounts the vacuum heatinsulating material of the present embodiment is excellent in therecyclability, there is no harmful effect to the human body, and thus itis expected to improve the heat insulating performance.

Namely, the refrigerator 100 of the present embodiment includes aplurality of storage rooms (the refrigerating room 150, the switchingroom 200, the freezing room 300, the vegetable room 400, and the icemaking room 500) including the refrigerating room 150 and the freezingroom 300, etc. provided with the opening/closing or drawer type doors(the refrigerating room door 160, the switching room door 210, thefreezing room door 310, the vegetable room door 410, and the ice makingroom door 510); the cooler 650 arranged at the rear face side of thestorage rooms through the partition wall for generating cooling air tothe storage rooms; the internal fan 660 for blowing the cooling airgenerated by the cooler 650 to each storage room; the cooler room 640arranged at the rear face side of the storage rooms through thepartition wall for containing the cooler and the internal fan; themachine room 601 arranged at the lower part or the upper part of therefrigerator main body for containing the compressor 600 which forms therefrigerating cycle; the heat insulating wall arranged between themachine room 601 and the cooler room 640; the vacuum heat insulatingmaterial 750 or 760 which is provided at either of the doors of thestorage rooms and the heat insulating wall, constituted by laminatedstructure of the organic fiber assembly 1 made by the sheet-shapedorganic fiber 2, and formed by inserting the core material 5 having acutting part, of which the end face has been cut, into the outer covermaterial 4, and sealing the sealing part of the outer cover materialaround the periphery of the sheet so as to hermetically seal the insidein the substantially vacuum state. In the above, the long fiber havingat least the same length as the organic fiber assembly 1 is used for theorganic fiber 2. Therefore, the heat insulating performance of the heatinsulating material 750 or 760 is good, the recyclability is excellent,the sealing fault, etc. may not occur, and thus the reliability is high.Accordingly, equipment such as the refrigerator 100, etc. using thisvacuum heat insulating material 750 or 760 has also high performance fora long term and good recyclability.

Here, the example case shows the vacuum heat insulating material 750 or760 is provided at the heat insulating wall between the machine room 601and the cooler room 640; however, a vacuum heat insulating materialopening part 71 can be applied to a cooling air passage. In this case,the vacuum heat insulating material 750 or 760 can be used for a sectionwall, a partition wall, or a heat insulating wall having a cooling airpassage. Further, the vacuum heat insulating material can be provided atthe heat insulating wall which forms the cooler room 640.

Reference Signs List

1: an organic fiber assembly; 1 a: an end face; 1J: a continuoussheet-shaped fiber assembly; 1Je: an end-winding end portion; 1K: afirst (organic) fiber assembly; 1Ka: a first (organic) fiber assembly;1Kb: a first (organic) fiber assembly; 1Kc: a first (organic) fiberassembly; 1Kd: a first (organic) fiber assembly; 1H: a second (organic)fiber assembly; 1Ha: a second (organic) fiber assembly; 1Hb: a second(organic) fiber assembly; 1Hc: a second (organic) fiber assembly; 1Hd: asecond (organic) fiber assembly; 2: an organic fiber; 2 a: a remainingfiber; 2 b: a cutoff fiber; 2 x: an organic fiber; 2 y: an organicfiber; 3: an air layer; 4: an outer cover material; 4 a: an openingpart; 5: a core material; 5 a: an end face; 5 f: a folding end portion;5 g: a flat part; 6: an adsorption agent; 7: a vacuum heat insulatingmaterial; 8: a spacer; 9: an external box; 10: an internal box; 11: afoam insulation; 12: a heat insulating wall; 41: an outer cover materialopening part; 45: a sealing part; 51: a core material opening part; 52:a through hole; 53: a notch; 55: a folded part; 56: a folded part; 57: afirst slit portion; 58: a second slit portion; 59: a folding part; 71: avacuum heat insulating material opening part; 72: a through hole; 73: anotch; 75: a vacuum heat insulating material opening part sealing area;100: a refrigerator; 110: an embossing; 150: a refrigerating room; 160:a refrigerating room door; 200: a switching room; 201: a containingcase; 210: a switching room door; 300: a freezing room; 301: acontaining case; 310: a freezing room door; 400: a vegetable room; 401:a containing case; 410: a vegetable room door; 500: an ice making room;510: an ice making room door; 550: a core material; 551 f: a foldingpart; 551 g: a flat part; 551Je: an end-winding end portion; 600: acompressor; 601: a machine room; 640: a cooler room; 650: a cooler; 660:a fan; 680: a cooling air passage; 690: an air passage; 702: a vacuumheat insulating material; 750: a vacuum heat insulating material; 750 a:a thin part; 750 b: a thin part; 750 c: a predetermined thickness part;751: a concave part; 752: a concave part; 753: a projected part; 760: avacuum heat insulating material; 760X: a concave part; 900: a controlboard; 910: a control board containing room; 1301: an original fabricroll; 1301 a: a main body part A; 1301 b: a main body part B; 1301 c: amain body part C; 1301 d: a main body part D; 1305: a first originalfabric roll; 1306 k: a second original fabric roll; 1311: a reel; 1312:a circumferential member; 1313: a clamp member setting part; 1315: arotating shaft; 1316: a circumferential member retaining shaft; 1316 a:a circumferential member retaining shaft; 1316 b: a circumferentialmember retaining shaft; 1316 c: a circumferential member retainingshaft, 1316 d: a circumferential member retaining shaft; and 1320: aclamp member.

The invention claimed is:
 1. A manufacturing apparatus of a corematerial of a vacuum heat insulating material comprising: a reel forwinding up a fiber assembly which is wound on an original fabric roll;and a forming member for retaining the fiber assembly on the reel andfor forming the wound fiber assembly into a flat-plate-shaped corematerial after removing from the reel the fiber assembly which has beenwound up on the reel at a predetermined number of times, wherein thereel comprises: a plurality of divided circumferential members; and atleast one retaining shaft configured to retreat and extend in a radialdirection for moving at least one of the plurality of circumferentialmembers radially, wherein after winding up the fiber assembly on thereel, the retaining shaft is retracted and the circumferential member ismoved inwardly in the radial direction to release tensional force of thefiber assembly for removing the fiber assembly from the reel.
 2. Themanufacturing apparatus of the core material of the vacuum heatinsulating material of claim 1, wherein the reel winds up a differentfiber assembly wound on a different original fabric roll whileoverlapping the fiber assembly and the different fiber assembly.
 3. Themanufacturing apparatus of the core material of the vacuum heatinsulating material of claim 1, further comprising: cutting means forcutting the fiber assembly which has been wound up on the reel from theoriginal fabric roll.
 4. A manufacturing apparatus of a core material ofa vacuum heat insulating material comprising: a reel for winding up afiber assembly which is wound on an original fabric roll; and a formingmember for retaining the fiber assembly on the reel and for forming thewound fiber assembly into a flat-plate-shaped core material afterremoving from the reel the fiber assembly which has been wound up on thereel at a predetermined number of times, wherein the forming membercomprises two clamp members arranged at opposite sides of the reel. 5.The manufacturing apparatus of the core material of the vacuum heatinsulating material of claim 4, wherein the reel winds up a differentfiber assembly wound on a different original fabric roll whileoverlapping the fiber assembly and the different fiber assembly.
 6. Themanufacturing apparatus of the core material of the vacuum heatinsulating material of claim 4, further comprising: cutting means forcutting the fiber assembly which has been wound up on the reel from theoriginal fabric roll.